Companies from virtually every industry are implementing decarbonisation strategies to reduce carbon emissions and minimise the environmental impact of their operations. One critical area for these efforts in process operations is dust collection systems.
In these systems, the filter bags can cake with dust and particulates if not properly cleaned. This restricts clean airflow and dust collector efficiency. Many dust collectors use pulse valves to send jets of compressed air through filters to break up and remove dust cakes. Producing this compressed air can be energy-intensive. Pulse valves that perform with maximum efficiency help optimise energy use and reduce emissions.
A new generation of high-performance pulse valves combined with intelligent compressed air monitoring systems and particulate monitoring can significantly improve the sustainability of dust collector systems, reliably reduce compressed air use and extend bag and filter life.
Maximise filter life in Dust Collection Systems
Many filter systems have valves that operate at an optimal peak pressure and specific valve response time to clean filters. If the pressure is too high, it can tear filters. If the valve response time is too slow or the pressure is too low, dust can remain on the filters and clog them. Both conditions can reduce filter life and cause excess waste.
The latest pulse valves feature a one-piece, two-way diaphragm that can provide optimal peak pressure and faster valve response time. A one-piece diaphragm allows airflow to travel under the diaphragm, restricting the flow much less and increasing air speed. This design efficiently clears dust from filters while preserving filter integrity, extending filter life and improving the dust collector system’s overall performance.
In addition, smart sensor technology helps promote sustainable cleaning practices to prolong filter lifetime. These sensors can provide accurate and reliable readings on particles, differential pressure and temperature in real time.
These data streams can be aggregated by a controller and translated by software into current filtration system insights and health diagnostics. Operators can use this data to identify and address clogged filters and other issues faster to prevent early filter failure.
Minimise compressed air consumption in Dust Collection Systems
Compressed air systems in many operations consume significant amounts of energy and prevent companies from reaching sustainability goals. It’s estimated that many facilities dedicate up to 30% of their electricity usage generating compressed air.
However, leaks and inefficient processes can waste a third of that energy, forcing compressed air systems to run longer and more frequently to supply the required pressure to efficiently actuate all the pneumatic systems within a plant.
Pulse valves that feature fast-opening and -closing technology can help reduce compressed air demand. Valves that have a slow response time stay open longer, which releases more compressed air. As compressed air generation is one of the more expensive processes in a facility, reducing use can also result in significant cost savings.
Compressed air consumption is also reduced by pulsing valves when filters need it, instead of following a standard pulsing schedule or differential pressure readings. These methods may cause valves to pulse and release compressed air when it may not be necessary.
An intelligent control system uses sensor information to optimise pulse frequency and precisely manage compressed air consumption. This can reduce energy use and support decarbonisation.
Monitoring overall airflow is another way to reduce compressed air consumption. Up to one-third of the compressed air a facility uses is typically lost to leaks. When facilities check for compressed air leaks on a preset maintenance schedule, leaks can go undetected for long periods of time before they’re addressed.
Using intelligent sensors to continuously monitor airflow and correct leaks earlier helps reduce the energy demand from compressed air systems. This technology can also significantly reduce maintenance time and costs compared to labor-intensive processes that check every tube on a schedule.
These smart sensors can easily integrate within existing systems and be used as stand-alone devices, or they can connect to new or existing controllers and visualisation software for advanced analytics.
Enhance system insight with SCADA software
To further optimise the efficiency of dust collection systems, supervisory control and data acquisition (SCADA) software can provide advanced system analytics and a holistic view of dust collection system health and performance. This insight can help improve sustainability decision-making as well as overall equipment effectiveness (OEE).
By extracting data streams from dust collector systems, the interface displays aggregated information and diagnostics, so operators gain more visibility into system performance. This is real-time status of every element in the system: each compartment, bag, row and solenoid valve.
Trends such as energy consumption can be identified, and maintenance can be better planned. If an issue arises, the software can send appropriate personnel detailed diagnostic alerts via text message or email.
A clear picture of every device in a dust collection system guides the shift from reactive to predictive maintenance approaches. Potential issues that impact energy efficiency are identified before waste gets out of hand, helping improve system efficiency and reducing both emissions and downtime.
Advanced software like this can be accessed remotely and puts the right information into the hands of the right expert at the right time. For example, chief sustainability officers and other stakeholders can access the dashboard to track sustainability progress and generate relevant reports on emissions, energy usage and more for government agencies.
Collect dust while reducing emissions
Pulse valves with high peak pressure and fast valve response time can significantly improve the overall energy efficiency of a dust collection system. They let facilities use only the compressed air needed to keep filters clean, improving cleaning efficiency, effectively removing particles from the environment and helping reduce the energy demands of the compressed air system.
Implementing this improved approach to dust collection system sustainability is easier to accomplish by partnering with an experienced technology provider. The right partner will offer a comprehensive portfolio of scalable products that include rugged, high-performance pulse valves as well as hardware and software that can work with a company’s existing equipment and networks. A provider like this can help organisations begin to digitally transform their dust collector systems or leap ahead on their journey.
Every machine and system across the factory floor is an opportunity to save energy and reduce emissions, including dust collector systems. Combining valves that optimise energy use with smart sensors, controllers and software provides device-level visibility and real-time control to maximise the performance of dust collector systems while minimising their environmental impact.
