FARR GOLD SERIES®
PROTECTS AGAINST DUST FROM ALUMINIUM LINISHING PROCESSES
Product: Farr Gold Series® dust collector
Size: GS16 with drop out section
Air Volume: 18.000 m3/hr
Application: Aluminium Linishing
Customer: Russell Consulting Scotland Ltd. (RCS)
End User: A global company involved in the avionics/ automotive sector, Scotland
Installation date: May 2013
Located on the West Coast of Scotland, a global supplier to the avionics and automotive sector was using wet type dust extractors in their manufacturing area to control and extract the dust produced by their aluminium linishing operations.
These wet extractors were noisy, inefficient and had to be cleaned out at least once a week causing serious downtime and loss of a day a week’s production. More importantly, the wet dust collectors did not comply with the new local and national emissions regulations.
The company’s core competence for engine components and peripherals ranks it among the top three systems suppliers worldwide for piston systems, cylinder components and valve trains, so meeting their own customers’ quality standards was critical. Their facility in Scotland manufactures precision bearings for the automotive industry and loss of production was potentially costing tens of thousands of pounds.
Colin Russell of RCS explains, “The wet dust collectors deployed on the one foot wide linishing belt sanders couldn’t meet the new standards required, and had to be cleaned out every Friday. This meant that in practice, four out of five days were spent producing, and one day spent cleaning up the extractors. Being a wet process, this had various implications.
“The linishing line was usually clean as a whistle on Monday’s start up, but because of the way in which the dust was being extracted, it got progressively worse so that by Thursday the quality of the linishing was materially affecting the aluminium surfaces that were being prepared for a further bonding process. This meant finished quality in this part of the process was becoming inconsistent and causing unnecessary problems for the quality inspections and production lines.
“The aluminium dust was being collected with all the water and eventually deposited into a large skip/tank, which then had to be cleaned out. This meant two operatives had be taken off the line and wearing wellies, waterproof clothing and other protective gear, had to go in to the extractors and the skip to get all the sludge out and into a wheelbarrow.
“To make matters worse, the metal dust was reacting with the water to produce hydrogen gas and was unstable, potentially inflammable and altogether a really nasty and potentially dangerous chore that no-one wanted to do!”
Russell Consulting Scotland Ltd.(RCS), a specialist providing independent advice for local exhaust ventilation systems, worked with their long-term business partner Camfil Air Pollution Control (APC) on behalf of the Scottish company to provide the best solution to the challenges outlined above.
The market leader in dry dust control systems, Camfil APC with RCS proposed a high-tech, custom-designed dust extraction system that would meet the new standards and surpass all the customer’s demands.
ATEX compliant as well…
The solution is based on a GS16 Farr Gold Series® dust collector. As aluminium dust is highly explosive, the dust extractor had to be fully ATEX compliant. The dust collector incorporates an integral drop out section to remove large volumes of dust from the airstream prior to the air passing through the filter cartridges.
This reduces the dust loading on the cartridges and so improves the filter life. Over 1000 kg per week of collected material discharges from the collector via three rotary valves into 1m3 flexible bags.
The GS16 Farr Gold Series was fitted with carbon impregnated HemiPleat® Gold Cone™ filter cartridges, and was supplied complete with an access platform as well as an energy saving variable speed drive controlled by a differential pressure monitor. The system installed provides highly efficient extraction ensuring that operators are protected from exposure to dust generated during the linishing process.
SEPA, the Scottish Environment Protection Agency has tested the system and they concluded that it is ‘an excellent installation’.
Net results: water-free dust extraction, continuous production, more consistent linishing quality
The Scottish-based global avionics and automotive supplier is delighted with their new dust extraction system. It has both improved the working environment and reduced maintenance costs. Moreover, production no longer needs to be shut down each week in order to clean the dust collector.
As Colin Russell says, “This solution works as well as it does because together Camfil APC and RCS listened to their customer, worked out the optimal solution, installed it expertly and have delivered results that surpass our customer’s expectations.
“Besides finding a better way to extract the aluminium dust, the Farr Gold Series dust collector needs far less maintenance and the carbon impregnated HemiPleat Gold Cone filter cartridges are relatively easy and far less time consuming to deal with, and are taken care of as part of an ongoing maintenance contract with us as well.
“The time saved has meant that production can run five days a week or more, instead of taking a day out with all the subsequent downtime. This is a massive result for this global supplier.”
Slideshow shows the old system being removed and our new specification design being installed. Move mouse cursor over images to see information tags.
Electrical energy consumption of the new system was only of 15kW in comparison to the massive 60kW required by the old system, quartering the electricity consumption.
25% more equipment efficiency allows more work to be contracted.
The client no longer has to pay two staff a day's wages to clean out filters every week.
Dust receptacle no longer requires to be manually emptied saving more labour costs.
Reduced staff resources spent on sweeping and cleaning.
Due to the decision to install a "dry collection" system, the client no longer hasw to contract a tanker to remove waste water.
The clients clean water bill was reduced.
Revenue is generated from the increased value of the waste material.
OEE(Overall Equipment Efficiency) was significantly improved due to the fact the old filtration system required cleaning every week. Dependent machinery was unusable on Fridays whilst the filters were manually cleaned. The process can now continue on a Friday with production running at 125% in comparison to the previous system.
Even with a whole extra day running time a week, the efficiency of Camfils unit results in an annual saving of £6,600 from electrical consumption alone. Imagine replacing 5 or 10 units.(*Annual cost based on £0.1/kWh)
Graph 1: Duct velocity of old system in green and new system in blue. As the week progressed the old system became less effective until Friday when production ceased in order for the LEV to be cleaned.