Extraction System

DUST FUME EXTRACTION SYSTEM

ATIPL stand alone dust extraction unit has been developed for the safe and effective removal of swarf and smaller particulates during processes such as routing, mechanical engraving, grinding and turning.

One of the main problems with other router extraction relates to the type of pump used. Most have brushed motors which are noisy in operation and frequently burn out, with the average life of brushes being around 800 hours.

The unit’s high vacuum pump is brushless and designed for continuous running to in excess of 30,000 hours before requiring servicing. The bag filter has a large 18 litre capacity and the HEPA filter is very high efficiency.

Standard Features

• Digital speed control – For variable airflow rates
• Auto sensing voltage (90-257v) for global use
• Small footprint
• Low noise levels
• Filters with long life and low replacement cost
• High vacuum pump for effective capture from source
• Brushless motor (can exceed 30,000hrs use before servicing)
• High efficiency 5 layer large capacity easy change filter
• HEPA filtration
• Filter full indicator
• Quiet in operation
• Small footprint

We are the leading firm in this industry offering Dust Fume Extraction System to our prestigious clients. This product is effective for suppressing dust, particulate and fumes while going through some processes called routing, grinding and mechanical engraving. Capable of providing high efficiency this extraction system is one of the demanded products of our company.

Features:

• Easy installation
• Rust and corrosion proof
• Less power consumption technology

Specifications:

• Air Flow Capacity: 600CFM (1000CMH)
• Suction Capacity (Velocity): 15-17 m/s (ideal condition)
• Blower type: Axial / Radial Fan
• Primary filter: Polyester / wire mesh / HEPA / Carbon
• Cabinet: 16G powder coated
• Control panel: Inbuilt / Separate
• Power watts: 360
• Noise level: 40-45 Db
• Weight Kgs: 60 Kgs. Approx

CYCLONE EXTRACTION SYSTEM

Multiclone

Cyclonic separation is a method of removing particulates from air or gas, without the use of filters, through vortex separation. Rotational effects and gravity are used to separate mixtures of solids and fluids. The method can also be used to separate fine droplets of liquid from a gaseous stream.

Dust laden gas or air enters the collector tangentially and follows a spiral path to the bottom of the cone. The centrifugal force created by the circular flow throws the dust particles toward the wall of the cyclone. After striking the wall, the combination of the gravitational and swirling forces causes the dust to move downward to the dust outlet. Pressure drop for normal operation is about 75-100 mmWG. They are very efficient in collecting dust particles down to 30 microns in size. Efficiency of the equipment depends on the material being conveyed, material/air flow rates and cyclone design. Depending upon the application, cyclone separator can be designed in single, twin and quad arrangement.

Type of Cyclone

• Single Cyclone
• Twin Cyclone
• Quad Cyclone

Multi-clone Dust Collectors Similar to Cyclone, ATIPL also manufacturers Multi-clone Dust Collectors wherever application of the cyclone could not serve the purpose and Multi-clone can provide higher efficiency.

Multi-clone Dust Collector consists of a number of small-diameter cyclones, operating in parallel and having a common gas inlet and outlet. Multi-clones operates on the same principle as cyclones, creating a main downward vortex and an ascending inner vortex. Multi-clones are more efficient than single cyclones because they are longer and smaller in diameter. The longer length provides longer residence time while the smaller diameter creates greater centrifugal force. These two factors result in better separation of the dust particles. The pressure drop of the multi-clone collectors is higher than that of single cyclone separators.

Advantages of Cyclones

• Stable pressure drop for a given gas flow
• Constant efficiency for a given particulate condition
• No moving parts; no replaceable filters, robust construction
• Ability to handle extremely high dust concentrations
• High temperature and pressure capability
• Low capital investment and maintenance costs
• Compact design

Reverse Air Bag House

The Reverse Air Bag House is a modular type dust collector in which each module act as a device which accepts the dust-laden gases, filters it, collects the dust and discharges the clean air.

The dirty air enters the side of the hopper so that, due to the low velocity, much of the entrained dust (particularly the large size of the dust particles) will drop directly into the hopper. Continuing upward, the air encounters the tube sheet where it passes through the collars and in to the filter bags. The dust in the air does not penetrate the bags and remains as a deposit on their inside surfaces. The air itself, however, does pass through the bag material, then continues upward and out through the top of the compartment from there it is directed through an exhaust manifold.

At specific intervals, a cleaning cycle is initiated in which the air flow through the module is stopped and air moving in the opposite direction is introduced. This reversed flow and the partial collapse of the bag which it produces causes the accumulated dust to break loose and fall out of the bags. The dislodged dust drops in to the hopper and is removed by dust handling equipment. After the dust had a few moments to settle, the valves are reset to their position for filtering.

The air to be filtered is moved through the dust collector by the ID Fan installed downstream of the exhaust manifold. Because air is being pulled through the system, each module discharges into an exhaust manifold which connects to the fan creating the suction. The main air valve and the reverse air valve are both located on the exhaust side of the module. The reverse air is forced into the compartment from the clean air side. The reverse air fan draws air from the system exhaust and blows it into the reverse air manifold which connects to each module at the reverse air valve.

The system requires the reverse air be hot to avoid the problems which would arise if moisture condensation occurs in the system – particularly on the bags.

Scrubber

Scrubbers have played a very important role in industrial ventilation for many decades. These are the only devices which can remove particulate matter as well as gaseous impurities. Wet scrubbing of industrial gases has improved over many years to accommodate fine cleaning requirements of today’s industry. Any activity like burning metal forming, chemical reaction or material handling will generate pollutants like particulate matter, unwarranted gases and these pollutants needs to be removed from the gas stream and cleaned gases are to be left in the atmosphere to ensure pollution free environment.

Scrubbers can be grouped into 2 types.  Type 1 is for particulate collection, where equipment like wet cyclones, cyclonic scrubbers and venturi scrubbers are involved, and type 2 is for gaseous absorption / removal, where equipment like static packed bed, dynamic packed bed, baffle plate scrubbers or impingement plate scrubbers are involved.

Venturi Scrubber

In its simplest form, a venturi scrubber consists of a restriction in a gas duct into which water is introduced. The scrubbing occurs at the restriction where high gas velocities atomize the water into fine droplets. After scrubbing, the gas and water are separated in a cyclonic separator, the water gravitating to a pumping tank for re-use and the clean gas leaving from the top of the separator.

Impingement Plate Scrubber

The gas enters the lower section of the scrubber and rises through a zone of spray, usually water, created by a group of low pressure sprays. These sprays humidify the gas and strip it of coarser dust particles. The gas is now prepared for intensified cleaning action during its passage through the impingement baffle plate stage, which is flooded with water or other scrubbing liquid during the cleaning process. The plate consists of two parts: A perforated sheet having circular boles & Impingement baffles above the sheet, a baffle being located directly above the sheet, a baffle being located directly above each perforation. When gas passes through these holes perforation, high velocity jet is created and each jet strikes against a baffle. Since the baffle is located at the vena contracta of the jet, the gas stream strikes the baffle at the moment of its greatest velocity giving the highest target efficiency for the pressure drop through the perforation.

Advantages of Cyclones

• High temperature gases will be cooled and washed in one equipment.
• Corrosive gases can be neutralized simultaneously with the collection of particulate matter.
• Soluable material may be recovered and pumped in slurry form for additional treatment, if necessary.
• Possibility of fire or explosive hazard is eliminated.
• When gases are near due point condition, wet collectors avoid the problem or building up sticky deposits on dry surface. This is an important factor to be considered before going in for a dry system with a pre-cooler. If the dew point is very high, one will have to insulate the dry system.

Typical Applications

Some of the typical applications for wet collectors are

• Gas cleaning for blast furnaces, boiler flue gas
• Black liquor recovery for pulp and paper
• Refusal incineration scrubbing
• Dolomite lime kiln exhaust
• Zinc oxide fume collection
• Aluminium smelting furnace exhaust ventilation
• Bagasse fired and oil fired stream/power generation

Apart from these, non-metallic scrubbers are used for acid scrubbing, SO x scrubbing and NOx scrubbing.

Centralised Dust Extraction System

The System the overhead system will be constructed in steel pipe using prefabricated steel bends and T pieces ensuring the required vacuum and air flow efficiency. The pipes will be attached using suitable clamps and ties and will be finished in white.

The Plant The extractor plant will be a 3 phase unit. The vacuum is a directly coupled dynamic compression unit made to the highest standards. Precision engineering and robust construction ensure a unit unequalled in performance and reliability. Filtration is via easily serviced filter cartridges that are capable of filtering 99.99% of fine dust. Filters are reverse cleaned with compressed air and dust is released into a disposable bag via a one-way shutter valve.

The extractor plant electronic management system incorporates:

• Automatic pneumatic filter cleaning unit.
• Service hours monitor.
• Remote on/off switching.

Energy Modules

8 service energy modules are provided for.

Each module incorporates two dust extraction points with a self closing flap and two air points with quick release couplings, both air points are regulated through a pressure regulator with gauge. Two 13amp power points are provided and each module also incorporates a compressed air filter unit isolator valve. To greatly enhance efficiency a remote extractor plant switching facility is provided with ‘led’ indicators to inform the user of system status.

Three phase supply An automatic filter cleaner is provided. This unit automatically initiates the filter cleaning cycle throughout the working day thus ensuring the continued suction performance and efficiency of the filters.

Air Supplies and Suspension System Air connections will terminate at low level at each service drop position, the system will be suspended from the air ring main. The system plant and work stations supplied, installed and commissioned complete.