In today’s episode of the Dust Safety Science podcast, George Armbruster, CEO and President of Industrial Intelligence Inc., talks about the development of the Continuous Dust Accumulation Monitor and Dust Mapping Survey.
George began his career in a laboratory, where he first engaged in source emissions testing, also known as stack testing. This role laid the foundation for his understanding of collecting air sample data. He and his colleagues would climb “smokestacks,” installing various testing devices to capture specific data, which were then analyzed by labs. The results were compiled into reports for the EPA.
George dedicated nine years to this field, leading the business for seven of those years as a partner. His work spanned across the United States, and in 2017, he transitioned to focusing on combustible dust. During this time, he worked with a company that sold ambient dust monitors, aiming to penetrate the U.S. market. This role provided him with a deep insight into the challenges and needs of different manufacturers in relation to combustible dust management.
What Inspired the Continuous Dust Accumulation Monitor?
After engaging with numerous customers, conducting dust hazard analyses, and consulting with insurance companies, George identified dust accumulation as a significant concern frequently highlighted in dust hazard analyses (DHAs) and housekeeping evaluations.
His experience with ambient dust monitors, which measure dust concentrations in the air, revealed that even minor leaks could lead to detectable levels of dust. This continuous leakage results in dust settling on surfaces like ceiling struts or equipment, which can easily become airborne under certain conditions, such as when a door opens or a fan activates, potentially shifting from low to high concentration due to accumulation.
George recognized a distinct need for a system capable of monitoring dust accumulation that would utilize technology over traditional visual inspections to address these challenges. The Continuous Dust Accumulation Monitor aims to quantify the amount of dust present in such areas to determine if it reaches dangerous levels or requires housekeeping actions. This data surpasses what can be achieved through visual and manual inspections alone.
George’s vision was to simplify the process of measuring dust accumulation. He aimed for a device capable of measuring dust thickness from 0 to 4 mm in 0.1 mm increments through a straightforward three-point calibration. By applying technology to this problem, George believed it would be possible to offer a critical solution to the industry.
What Did the Development Process Look Like?
Recognizing the need for expert collaboration, in 2019 George assembled a highly skilled team of researchers, including engagement with WPI’s combustion laboratory and Dr. Rangwala. The team was diverse, comprising a physicist, electrical engineers, and mechanical engineers, all contributing to the project’s development.
They held several ideation sessions, initially exploring 13 different sensor technologies for measuring dust accumulation. This list was refined to five candidates for proof-of-concept development, and then further narrowed down to three from which prototypes were created. Through prototype and bench testing, the team decided on machine vision technology as their focus. They developed a basic 3D prototype that operated with camera and LED lighting technologies, initially run from a laptop without a dedicated circuit board.
The development process involved numerous iterations of prototyping and testing, both in-house and at WPI, to hone in on a design that provided reliable results. After three or four iterations, they identified their minimum viable product (MVP). The next challenge was designing an enclosure that met Class II, Division 1, Groups C, F, and G certification requirements. A consultant specializing in Underwriters Laboratories (UL) standards was brought in to collaborate with the mechanical and electrical engineers on the team to achieve a design that could withstand FM certification testing.
The firmware development alone spanned nearly two years. As George put it, “It’s been a long road, but we’re at the finish line.”
How Was the System Tested?
Due to non-disclosure agreements, George refrains from specifying locations, but his team conducted trials at a mining processing company, which, while not dealing with combustible materials, presented significant dust challenges. These trials were crucial for assessing the performance of their camera technology. Further testing took place at a carbon black facility, where they focused on assessing the durability of their system. Much of their experimental work, including trials with various dust types like peat dust at different micron sizes, was carried out at WPI. These tests revealed significant insights, such as dust particles under 50 micrometers tending to adhere to the sidewalls of their equipment.
Through these investigations, George’s team developed a system to detect dirty optics and patented both passive and active methods for lens cleaning. Additional testing was performed under varying humidity conditions using fine sugar dust at different particle sizes, which provided valuable data for refining their technology. Experiments with both dark and light dust, alongside adjustments to LED lighting, led to algorithmic tweaks to improve accuracy.
With a wealth of data supporting their confidence in the system’s performance, George and his team are now focused on achieving FM certification for their innovative dust monitoring solution.
What is the Dust Mapping Survey and How Was It Developed?
One of the primary questions George and his clients faced in the context of ambient dust monitoring was the optimal placement and quantity of monitors required in a given area. Rather than relying on guesswork, George collaborated with his team and WPI to adopt an engineered approach.
They experimented extensively with deploying pre-weighed filter media across a matrix within room areas, allowing the samples to collect dust over periods ranging from 7 to 30 days. They also documented the layout of the room and the specific locations of the samples. After this duration, the samples were retrieved and sent for post-weight analysis.
This meticulous process enabled them to create a dust deposition map for the area, clearly showing where dust accumulated over time and quantifying the amount of dust on various surfaces. Armed with concrete data rather than assumptions, they could then provide clients with informed recommendations on where to install dust monitors. However, they proceeded with caution to avoid overstepping any boundaries in the absence of established standards.
This initiative also revealed that the method could serve as a standalone service, offering a means to evaluate dust levels objectively, beyond the subjective assessment typically provided by Room Surface Area (RSA) and Dust Hazard Analysis (DHA). By producing a dust map with quantitative analysis, they facilitated dust mapping prior to filtration, identifying accumulation points and areas of concern. Furthermore, they could demonstrate the effectiveness of dust mitigation devices through before-and-after comparisons, proving the method to be both straightforward and cost-effective.
What’s Next?
George and his team are at the final stages of launching their dust mapping survey commercially. They have already produced 2000 units and anticipate engaging with various markets over the coming months to raise awareness across different industries. The Continuous Dust Accumulation Monitor is undergoing certification by FM, with expectations set for the certification to be finalized by late August or early September. Once certified, they plan to begin installations at customer sites. In preparation, George is focusing on refining their sales strategy, including collaborating with distributors and sales groups, to ensure they are well-informed about the product ahead of its commercial release.
Conclusion
By merging his deep industry knowledge with a collaborative approach involving experts and advanced technologies, George has spearheaded the development of solutions that not only identify but also quantify dust accumulation risks. The Continuous Dust Accumulation Monitor, soon to be FM certified, promises to provide invaluable insights into dust levels in real-time while the Dust Mapping Survey offers a blueprint for optimal monitor placement.
As George and his team prepare to bring these innovations to the market, they continue to focus on educating industries about the importance of dust management and the potential of these technologies to enhance safety protocols. Their journey reflects not only the evolution of dust safety science but also the potential for dedicated professionals to create meaningful change through innovation and perseverance.
If you would like to discuss further, leave your thoughts in the comments section below. You can also reach George Armbruster directly:
Website: https://www.industryintel.com/
LinkedIn: https://www.linkedin.com/in/georgetarmbruster/
Email: [email protected]
If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.
Resources mentioned
The resources mentioned in this episode are listed below.
Dust Safety Science
Combustible Dust Incident Database
Dust Safety Science Podcast
Questions from the Community
Companies
Industrial Intelligence Inc.
Publications
Dust Safety Journal Issue #7
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