Stable and On-demand Dust & Vapor Extraction
‘Extraction on demand’ is an important trend in today’s high-end industrial extraction systems. Extraction systems that can switch lines on and off are the new standard. This is because it provides the following benefits:
- Increased flexibility for manufacturing plants
- Allows more frequent batch changes and smaller production lots
- Providing stable extraction conditions to critical production machines.
The carrousel integrates all piping branches into a central point. It operates fully automatically since it is equipped with smart self-learning software (adaptive gain) to minimize false air consumption and optimize energy usage with fan frequency drive control. This makes the dust collection system as balanced, available and flexible as required. The central carrousel is integrated into the piping network, connected to the filter unit and fan. Stable dust collection systems.
What steps to take to come to the right Air Flow Stabilization for your production process
It starts with selecting the correct filter type; high-end filters with pressurized air cleaning (pulse on-demand jets) can take the form of an envelope, bag, or pleated element filters. All these elements are installed in a standardized modular filter housing. The primary filter principle is either down-flow for rather light dust or pre-separated up-flow in the event of more abrasive dust.
Product filters with extremely high dust loadings (150 gr/m3) require the most advanced bag fixation system to prevent dust leakage. To determine the appropriate filter size, two design parameters have to be considered:
- The air-to-cloth ratio, meaning the speed of impact of dust particles against the filter cloth
- The can- or interstitial velocity, a function of bulk density, particle size distribution, dust agglomerating and inlet loading.
By combining full scale practicum and lab testing with fluid-flow modeling, the optimal filter element and bag spacing can be accurately determined.
The next step is to design a fit-for-purpose product release geometry. This provides the balance between standardization (economics) and long life-time performance at a guaranteed dust emission norm
An unique approach of Automated Air Flow Stabilization Technology
To guarantee creating healthy work environments, JOA has been realizing tailor-made air pollution control systems since 1998. We distinguish ourselves through disruptive, innovation based systems, based on data collection and modelling. Above all, we know that the only way to ensure the best working conditions for your employees is to eliminate even the smallest airborne dust particles and fumes. Our technology provides this and enables more efficient usage of raw or base materials, resources, and energy.
Applications of Air Flow Stabilization
JOA has a vast track record implementing on-demand extraction for various industries and production processes. Automated Air Flow Stabilization can be applied in a multitude of flexible systems, including:
- Dust Collection Systems
- Vapor Extraction Systems
- Central Vacuum Cleaning (CVC) units
- Secondary applications
Air Flow Stabilization ensures stable extraction at any point or branch. It has the opportunity to vary with the extraction point simultaneous in operation. In the occasion a reduced number of extraction points would be active, the system enables for reduction of the central fan speed. However, it will still maintain stable and sufficient extraction at the points in operation.
The Philosophy behind Automated Air Flow Stabilization:
More common and standard extraction systems combine all extraction points to a single header, which ends in a central filter and fan. To keep the velocity in the header constant at the required conveying velocity, all extraction points have to open continuously. This inflexible system uses much energy, because the equipment (e.g. Fans, Filters) has to be able to deliver a large capacity.
The alternative is to design a flexible extraction system, with all the piping directly connected to the filter. For this parallel system an extraction point (or branch) may be taken out of service without any negative effects for system instability etc. The disadvantage of this system is the high quantity of pipes needed.
On-demand Extraction considerations
- All the extraction points or branches are connected to local Carrousels using parallel piping. This allows an extraction point to be taken in or out of service and still keep the system in balance.
- The JOA Carrousel combines the advantages of a standard dust or vapor extraction system and using Air Technical Modelling and Restrictor Patents with the flexibility of the parallel extraction principle.
- The JOA Carrousels are individually maintained automatically at the set negative pressure by dosing false air.
- Energy can be saved if the dedusting fan reduces speed, on that moment the false air amount will be reduced, even as the total flow towards the dust collector.
- As reduction of the total flow towards the dust collector may lead to a higher dust settlement amount. For this reason a flow measurement is done between dust collector and the fan. System limits are also set, depending of the type of dust.
- To apply the patented Air Flow Stabilization Technology, JOA applies Air Technical Modelling, Restrictor Designs and Deflector Hood patents for very precise balancing and flow distribution.