Complete Guide to Ambient Fume Extraction

Components of an Ambient Air Filtration System

One of the first major choices to be made in choosing a solution for industrial dust and fume control is one between a filtration system and an exhaust system. A filtration system purifies the air, which can be recirculated into a facility, whereas a simple exhaust system just vents the air to the outside. Choosing between ambient air filtration and exhaust ventilation depends on the specific requirements of the workplace, the nature of the contaminants, and the desired level of air quality management.

Learn more: Complete Guide to Ambient Air Filtration

Dust Collector

The dust collector is the heart of the ambient fume extraction system, as it houses the fan/blower components that are critical in creating air circulation throughout a facility. An ambient system may have a single, large centralized dust collector (often located outside the facility) or several smaller collectors located on the floor.

Types of Dust Collectors for Ambient Air Filtration System

There are different types of dust collectors, the most popular of which include the baghouse, cyclone and cartridge collectors.

The dust collector is the heart of the ambient fume extraction system, as it houses the fan/blower components that are critical in creating air circulation throughout a facility. An ambient system may have a single, large centralized dust collector (often located outside the facility) or several smaller collectors located on the floor.

Types of Dust Collectors for Ambient Air Filtration System

There are different types of dust collectors, the most popular of which include the baghouse, cyclone and cartridge collectors.

Baghouse: These systems utilize fabric bags to capture the particles. They are most efficient for applications with high dust loads and air volumes. Foundries and cement manufacturers are just two examples of users implementing this type of collector.

Cyclone: Dirty air enters the collector and is forced into cyclonic/spiral action, which separates dust from the air. These are low-maintenance systems, but they are intended for larger dust particles and might not be effective enough to meet PELs for facilities where emissions include small particles. For this reason, they are not commonly used in ambient air filtration applications, which generally focus on light, airborne dust.

Cartridge dust collectors: The pleated filter media used by cartridge dust collectors is highly effective in removing extremely small particles from the air. Cartridge dust collector filters are most commonly made in a cylindrical or oval shape, and the media in them will differ depending on the environment in which they are used.

Learn More About Cartridge Dust Collectors
Advantages of Cartridge Dust Collectors for Ambient Filtration 
For ambient air filtration applications, cartridge dust collectors are by far the most commonly used. Cartridge collectors have a number of advantages for ambient dust collection.
  • The cartridge filter dust collectors are highly versatile, as cartridge filters come in a variety of media types for different dust types/particle sizes.
  • These collectors are made so the filters can be easily changed, which reduces downtime.
  • This dust collection system is more compact than cyclone and baghouse collectors with similar airflow (CFM) capacity, reducing floor space requirements.
  • They are more energy efficient.
  • The best cartridge air filters will contain 99% or more of particles in the submicron range, making them appropriate for weld fumes and other applications producing small, fumed particles.
  • The enclosed design of the system aids in reducing fan/blower noise.

Air Intake

Optimal airflow and capture efficiency are key components of the placement of intake valves on ductless and ducted air filtration systems.
  • The ductless system relies on the air intake plenum, which pulls air into the collector. Since there are no ducts involved, it’s important to carefully plan the placement of the air filtration units within the facility so the air is optimally circulated and captured.
  • The air intakes in a ducted system must be positioned within reasonable proximity to the fume/particulate source. This ensures that contaminants enter the ducts rather than drift throughout a facility.

Fans and Blowers

These components (part of the dust collector itself) create the necessary airflow to draw contaminated air into the system and push filtered air back into the workspace. They must be powerful enough and generate enough static pressure to ensure adequate air circulation throughout the area being treated.

Ductwork

With the ducted air filtration system, the placement of the network of ducts must be carefully planned to maximize airflow efficiency and achieve proper contaminant capture. This includes consideration of every bend and turn in the ducts for reduced air resistance. Most designs feature ducts placed close to the ceiling, where rising emissions are captured and passed through the intake ducts to the dust collector. The ducts are connected to a large dust collector either inside or just outside of the facility where the air is cleaned. The air is then routed back inside, and the clean air is dispersed via the air supply ducts.

Filters

Dust collector cartridge filters are available in various filtration efficiencies and media types. This range of filter options accommodates filtration needs that can differ drastically from one facility to the next. The decision-making process considers many variables, the most important of which include the size of the particles being captured, the required capture efficiency to meet PELs, whether moisture or oil is present in the captured air, the abrasiveness of the particulate, whether particulate is sticky or hygroscopic, and if there are static risks involved.

Download the Buyer's Guide to Industrial Pleated Cartridge Filters

To achieve PELs, filtration efficiency is of critical importance. The most widely used cartridge filters in industrial settings have a Minimum Efficiency Reporting Value (MERV) between 11 and 16. The higher the MERV rating, the more efficient the filter is at capturing smaller particles. However, there is a tradeoff: higher MERV ratings also mean increased airflow resistance, which can impact the lifespan of the filter and the energy consumption of the system.

Pulse Jet Cleaning

To prolong the life of the filter, the dust collection system should be equipped with filter pulsing mechanisms. This technology delivers periodic pulses of compressed air across the entire ambient air filter, which dislodges particulates that have become caked onto the media. Online pulsing is used while in operation to prevent particles from embedding into the filter, while offline pulsing is used to remove the particles from the filter and allow them to fall into the containment. The dislodged particulate then falls into a capture compartment where it can be disposed of. This process maintains a clear path for air to flow into the filters and for clean air to be pushed out of the system, but it also prolongs the overall lifespan of the cartridge filter by ensuring that every part of the filter is not subjected to excess filter loading.

Control System

The control system serves as the central processing unit of the air filtration unit, functioning as its brain. Typically, it includes a touch-screen human-machine interface (HMI) that allows control over various functions. These functions include adjusting fan speed, starting filter pulsing, monitoring maintenance schedules, and conducting built-in diagnostics for performance monitoring. Additionally, users can access settings, check filter differential pressure, conduct pulse system testing, make remote start adjustments, and manage start/stop time clock controls, among other available features.

Containment Bin

The collection bin is designed to gather and store the particulate matter and dust that is captured by the filtration system. The size and capacity of the bin are determined by the volume of dust generated and the frequency of maintenance and emptying schedules.
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