Areas to target in analyzing your dust collection system are: the filter cleaning system (i.e., compressed air consumption on reverse pulse jet systems); pressure drop across the filter media; and the inlet and outlet conditions of the main fan. If any of these areas are not designed correctly for your application and configuration, then your energy consumption could be improved by having your system optimized.

For example, on applications where your system is servicing workstations that are only used intermittently, the use of a Delta-P cleaning process versus a Continuous Time Interval cleaning process would greatly reduce your compressed air consumption. The Delta-P controller starts the cleaning process when the pressure drop across the filter media reaches the high setting and continually cleans all element rows in a timed sequence until the pressure drop reaches a low setting. Therefore, the filter media is only cleaned when dust is being collected and accumulated on the filter media because of workstation utilization. Conversely, the Continuous Time Interval process cleans without regard to dust accumulation and pressure drop. This Delta-P method of cleaning saves energy and extends the life of the filter media by reducing the number of the stress cycles on the filter elements compared to the high cycle count of timed interval cleaning.

Another more forward thinking method to reduce your energy consumption is to initially design or now turn your system into an “On Demand” dust collection system. Only about ½ of a typical plant’s equipment is running at any given time. Therefore, it is not necessary to have your entire collection system running the entire time.

Automated gates, combined with a variable frequency drive on the main motor can be engineered to provide you with “On Demand” dust collection. Sensors are installed on each machine that signal a controller to open and close automatic gates according to whether the machine is running or not running. When a machine is not in use, the system shuts down the dust collection to that machine. As the demand on your system is reduced, a VFD controller also regulates the fan speed. Thus the demand and energy consumption to provide your plant dust collection is greatly reduced, as is your energy bill. Be sure that the pipe (duct) system and control logic are designed so the minimum transport velocity is maintained in all pipe sections.

Working with the right dust collection expefarts and utilizing the right equipment can provide you with an optimized system that can save you as much 70% on your dust collection energy cost.