DUST COLLECTOR

FREQUENTLY ASKED QUESTIONS

VOLUME 2
When evaluating dust collection systems, there are many aspects to look at. This version of
our Frequently Asked Questions focuses on some of the equipment and factors besides the
actual dust collector that can affect the system’s performance. Have a look through some of
the common questions and answers to help with your overall outlook on how your dust collection
system is performing.
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Q1 What is the suggested maximum
loading for dust collectors?
Dust collectors, such as baghouses and cartridge collectors, use Dust Collection
Dust Collection FAQ
bags or filters to separate the dust from the air. Since they use a FAQ
Q1)
fabric filter, too much dust over a short period of time can cause
What is the suggested maximum
Q1)
the unit to not work correctly. Baghouses with dust concentrations loading for dust collectors?
over 5-7 grains/cubic foot and cartridge collectors over 2 What type of dust collector do
Q2)
I need for my application?
grains/cubic foot can have operational and maintenance issues.
Why is particle size distribution
To calculate your loading you take the dust loading in the collector Q2)
so important?
(lbs/hr) and multiply it by 7,000 grains per lb. You then calculate
Q3) information do I need to
What
the total CF in an hour. You divide the grains per hour by the total size my dust collector?
What are the benefits of using a
airflow in an hour to get grain/ cubic foot. cyclone as pre-filter for a
Q3)
baghouse/cartridge collector?
EX: 2 lbs/hr dust loading in 1000 CFM
IsQ4)
my dust explosive?
2 lbs/hr * 7000 grains/lb = 14,000 grains/hr How does the fan wheel style
Q4)
affect my performance?
1000 CFM * 60 min/hr = 60,000 ft3/hr Can I increase the airflow
Q5)
through my dust collector?
(14,000 grains /hr) / 60,000 ft3/hr = 0.23 grains / ft3 Why do you recommend
Q5)
differential pressure gages?
If your loading is greater than the above values, you are
IQ6)
replaced my baghouse with
overloading your dust collector. The filters will probably have a a cartridge collector and it
What is a DHA?
very short life. The airflow through your system decreases rapidly doesn’t work as well, why?
and dust is no longer being picked up at the pickup points. Filters Q7)

– the most basic dust collectors. Disposable filters are effective Why do you recommend
with very low concentrations of dust particulate. Filters are dampers?

replaced, once they are plugged up. Cyclone pre-filters can be Q8)
used to increase filter life. How does ductwork affect my
system?

Q9)

Q2 Why is particle size distribution

Do I have the right type of hood
for my application?

Q10)

so important? I have a used dust collector; will

it work in my application?

The particle size distribution of a dust is important because dust

collectors have gaps to let air through the filter while collecting the
dust. Whether the gap is in a filter or the outlet of a cyclone, dust
can escape through this gap and not be collected. P2
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Dust collectors have a removal efficiency curve, that will provide
the expected removal of dust at a certain particle size. In order to
accurately predict the removal efficiency of the dust collector, the
particle size distribution must be compared to the removal
Dust Collection FAQ
efficiency curve and calculated.
Q1)
Baghouse and cartridge collectors have very high removal
What is the suggested maximum
efficiencies down to 1-2 micron dust sizes. That is the reason, the loading for dust collectors?
manufacturers don’t ask for particle size distributions on many
Q2)
applications. Only at submicron particle sizes will they be needed.
Why is particle size distribution
Cyclones on the other hand are less efficient and require particle so important?
size distributions on most applications.
Q3)

What are the benefits of using a

cyclone as pre-filter for a
baghouse/cartridge collector?

Q3 What are the benefits of using a Q4)

How does the fan wheel style

cyclone as pre-filter for a baghouse / affect my performance?

Q5)
cartridge collector?
Why do you recommend
differential pressure gages?
If you are working with a high value material or product, have high
maintenance costs to the baghouse/cartridge collector, or want to Q6)

avoid cross-contamination, then you should investigate using a What is a DHA?

cyclone ahead of your baghouse or cartridge collector. The Q7)
cyclone will allow you to recover the dust without contamination
Why do you recommend
from the filters. The filters in a baghouse or cartridge collector use dampers?
a dust layer built up on the filters to collect the dust from the
Q8)
airstream. During the process of filter cleaning, dust from this layer
How does ductwork affect my
is dislodged and falls into the hopper. Any particulate from prior system?
batches can cause contamination of the dust.
Q9)

A cyclone, on the other hand, collects the dust and deposits it in Do I have the right type of hood
the hopper continuously. There is very little dust buildup inside of for my application?

a cyclone. This minimizes the chances of contamination from prior Q10)

batches. Since there aren’t any filters, a cyclone can be washed I have a used dust collector; will
or wiped out to remove the prior batch particles. it work in my application?

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Q4 How does the fan wheel style
affect my performance?
The exhaust fan could be the most important component in the dust Dust Collection FAQ
collection system. It provides the motive force for the whole system. If
it isn’t performing as required, the system will fail. The proper fan Q1)

impeller (wheel) must be used if the fan is to operate correctly. What is the suggested maximum
loading for dust collectors?
There are three types of wheels/impellers:
Q2)
a) Radial wheel (Ex. open material handling and material handling) Why is particle size distribution
- These wheels should be used when the fan is on the dirty side so important?
of a dust collector or after a dust collector where a large amount Q3)
of dust remains in the airstream (ex. after drop out box). The
What are the benefits of using a
wheel is designed so it can handle dust in the air. The open type
cyclone as pre-filter for a
wheel is used when there is a high dust loading and/or the dust baghouse/cartridge collector?
is fibrous. Its design helps prevent the dust from wrapping
Q4)
around the wheel.
b) 2) Air handling wheel – The air handling wheel is designed How does the fan wheel style
affect my performance?
for clean airstreams or extremely light dust loading. These
wheels should always be used on the clean side of and dust Q5)

collector and never on the dirty side. They are usually more Why do you recommend
efficient in air movement than the radial wheels. differential pressure gages?
c) 3) Axial wheel – These wheels are usually never used on Q6)
dust collection systems. They will move a lot of air, but without
What is a DHA?
much force behind them. If possible, stay away from axial fans
on your dust collector system. Q7)

Why do you recommend

If you are having issues with the fan on your dust collector, check the dampers?
wheel. Make sure you are using the proper type.
Q8)

How does ductwork affect my

system?

Q5 Why do you recommend Q9)

Do I have the right type of hood

for my application?
differential pressure gages? Q10)

The differential pressure gage is an often overlooked piece of I have a used dust collector; will
it work in my application?
equipment on dust collectors, especially cyclones. By measuring
the differential pressure across your dust collector, you are
monitoring your system performance.
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If the differential pressure gage suddenly changes, it is telling you
something has recently changed in your system. If you see a
gradual change in the differential pressure, then it is telling you that
the system is gradually changing.

A sudden change is telling you that the airflow has suddenly

Dust Collection FAQ
increased or decreased. This could be caused by a variety of
reason (plugging of filters, opening of damper, closing of damper, Q1)

etc.) When you see this happen, your removal efficiency will be What is the suggested maximum
affected so it’s better to start identifying the issue before you are loading for dust collectors?

forced to. Q2)

Why is particle size distribution

A gradual change is telling you that the ductwork or filters are so important?
starting to plug up. This could be normal operating conditions or
Q3)
caused by a change in process. When you notice a gradual
change in the pressure drop, schedule a maintenance inspection What are the benefits of using a
cyclone as pre-filter for a
before it gets too drastic. That way you won’t be forced shut down baghouse/cartridge collector?
in an emergency. Q4)

How does the fan wheel style

affect my performance?

Q5)

Q6 What is a DHA? Why do you recommend

differential pressure gages?

Q6)
With the release of NFPA 652 and 654, manufacturers that create
dust in their processes are required to conduct a Dust Hazard What is a DHA?
Analysis if the dust is explosive. The Dust Hazard Analysis is Q7)
retroactive, so all manufacturers are required, no one is
Why do you recommend
grandfathered in. dampers?

Q8)
The DHA should be as simple or as complex as the process and
needs to be documented for OSHA. The main purpose of the DHA How does ductwork affect my
system?
is to educate the owner and operators on the true hazards and
dangers they are facing with their dust, and to make sure they take Q9)

the proper precautions with it. The DHA is there as a tool to Do I have the right type of hood
for my application?
prevent loss of life, equipment, production time, and capital.
Q10)

I have a used dust collector; will

it work in my application?

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Q7 Why do you recommend
dampers?
Dust Collection FAQ
Dampers are used in dust collection systems to control the airflow
to specific branches of the ductwork. This is done by opening or Q1)

closing the damper. Air, like water, travels the path of least What is the suggested maximum
resistance. By using a damper, you are changing the resistance loading for dust collectors?

to the air. Every dust collection system should have a manual Q2)
damper near each hood/pickup point to balance the system. This Why is particle size distribution
makes sure that the system is properly operating. An unbalanced so important?

system could cause too much air to be pulled from one area Q3)
(causing loss of product) while in another area not enough airflow
What are the benefits of using a
is available to capture dust. Other times, a soft connect (space cyclone as pre-filter for a
baghouse/cartridge collector?
between flanges) is used to control airflow at a pickup point.
However, this isn’t very efficient. This keeps the airflow in that area Q4)

constant, but it’s picking up air from an area where it isn’t required. How does the fan wheel style
A damper would work much better, since you are only moving the affect my performance?

air in the area you need. Soft connects are only advantageous Q5)
when you are looking to cool down an airflow using outside air. Why do you recommend
Dampers can also be used to shut off portions of the system that differential pressure gages?

are not being used, thereby allowing a smaller system. Q6)

What is a DHA?

Q7)

Q8 How does ductwork affect my Why do you recommend

dampers?

Q8)
system? How does ductwork affect my
system?
Ductwork is usually by far the largest component and often the
Q9)
most overlooked. Depending on the size of your system, the
ductwork can span hundreds of feet and have dozens of side Do I have the right type of hood
for my application?
streams. The ductwork is like railroad tracks, it moves the dusty
Q10)
air from one place to another.
I have a used dust collector; will
Often times, additional lines will be added to a dust collector it work in my application?
system after installation. Without proper evaluation of the system,
this could negatively affect the performance of the whole system.

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This means that just because the dust collector system was
operating correctly before, it might not after an additional pickup
point or hood is added. What happens is that when you add
additional pickup points, you change the balancing of the system.
This could change the airflow to each and every hood and pickup
point in the system, so while the system was originally adequately Dust Collection FAQ
venting an area, it might not after a change.
Q1)
A few things can be done to address this, such as changing fan What is the suggested maximum
speed, adding dampers, modifying ductwork, etc. The main thing loading for dust collectors?

you need to keep in mind is that if you slow the airflow through Q2)
ductwork too much, you begin to build up dust within the line. This
Why is particle size distribution
will further restrict your airflow and become a fire / explosion so important?
hazard. Q3)

What are the benefits of using a

cyclone as pre-filter for a
baghouse/cartridge collector?

Q9 Do I have the right type of hood Q4)

How does the fan wheel style

affect my performance?
for my application?
Q5)

The key to a proper operating dust collection system is that the Why do you recommend
differential pressure gages?
right hoods and pickup points are used. An improperly designed
hood will either not collect all the dust, or required more airflow Q6)
than would efficiently work. The first could cause fire and/or What is a DHA?
explosion issues, while the 2nd will cause greater capital and
Q7)
operating costs. The first step is to check out the Industrial
Why do you recommend
Ventilation Handbook ( https://hubs.ly/H08Lh7p0 ). It will provide dampers?
you with recommended hood designs, airflow requirements, etc.
Q8)
You can also contact engineering firms, consultants, and
manufacturer representatives to help you select the proper hoods. How does ductwork affect my
system?

Q9)

Do I have the right type of hood

for my application?

Q10)
Think Differently
I have a used dust collector; will
it work in my application?
At Aerodyne, we approach problems differently, with unique
technology and fresh perspectives that solve your tough dust
challenges.
P7
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Q10 I have a used dust collector;
will it work in my application? Dust Collection FAQ

When dealing with used dust collectors, the best policy is to size Q1)

your dust collection system as you would normally and then What is the suggested maximum
evaluate the used collector to see if it will work. This means, loading for dust collectors?

starting at your pickup points and sizing the hoods and calculating Q2)
the required airflow. Then sizing the ductwork and calculating the Why is particle size distribution
static pressure required. You can then look at your used dust so important?

collector and see if it will work with your required airflow. If it will, Q3)
then calculate the pressure drop through the dust collector and add
What are the benefits of using a
it to the system drop and you can then evaluate the exhaust fan. cyclone as pre-filter for a
baghouse/cartridge collector?
Once you have confirmed that the used dust collector will work, it
would be prudent to have it inspected and brought into working Q4)

order. You can then begin operating. How does the fan wheel style
affect my performance?

Q5)

Why do you recommend

differential pressure gages?

Q6)

What is a DHA?

Q7)

Why do you recommend

dampers?

Q8)

How does ductwork affect my

system?

Q9)

Do I have the right type of hood

for my application?

Q10)
Think Differently
I have a used dust collector; will
it work in my application?
At Aerodyne, we approach problems differently, with unique
technology and fresh perspectives that solve your tough dust
challenges.
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