According to Ptronik formerly P Thomas Electronics , A dust extractor which electronically monitors dust emission helps reduce pollution. It also reduces costs through reducing electricity consumption, increases the life of dust bags and improves staff productivity.
In the current political climate, there is a growing demand for manufacturing plants to become cleaner and more environmentally responsible.
One way to improve air quality and reduce power consumption is to look at the resources used in production. For many companies, electricity is a huge expense. The forecast power cost increase of up to 60% over the next few years will put pressure on companies to reduce power consumption.
Dust collectors commonly carry out fixed interval pulsing of valves, regardless of need. As they do not have an ‘on demand’ cleaning function, there is no flexibility to operate dust extraction according to need.
Pulsing is a compressor generated high pressure air stream which goes through a valve and into the dust bags. The air stream shakes dust from the bags and into a bin. Generating these airstreams requires a lot of electricity. Most companies use this common procedure.
The solution is to reduce the pulsing and therefore the need for electrically generated compressed air. Using differential pressure and on demand cleaning together with a programmable timer board will provide greater dust control over dust extractors. With this method, savings can be as high as 70%, with an average of 30-40%.
Another cause of compressed air over-use is valve malfunction. There are two ways that this can occur. The first is when the valve is always open, allowing a constant and uninterrupted stream of compressed air through. The second is when the valve is constantly closed. This will cause the dust extractor bags to be clogged up with dust and a significant increase in differential pressure. A message will then be sent to the dust controller to pulse more frequently. Both problems will generate a much higher demand for compressed air and therefore the power use will be increased.
To monitor and attend to these problems right away, installations of electronic sensors will immediately indicate mechanical or electrical fault in the valves. An alarm will be sent back to the master controller so action can be taken.
Another common pollution factor for the manufacturing plants with dust collectors is the leaking of dust through thorned dust bags. Many companies have not installed sufficient monitoring systems, but rely on manual checking on a regular interval. This procedure causes significant dust concentrations being sent out through the clean air stack.
To avoid any dust pollution it is possible to electronically monitor dust emission. To electronically monitor the dust emission a dust sensor connected to a master controller, which controls the pulsing, will give an alarm right away when dust has been detected.
Installation of automated preventative systems in dust extractors will result in significant cost savings. It can also improve environmental performance and occupational health standards.