In today’s episode of the Dust Safety Science podcast, John Schubert, founder and Manager of Engineering at Schubert Environmental Equipment and ReplaceAIR, reviews the use of wet dust collection for low density materials. This episode is a follow-up to an earlier airing about using this collection method for metal dust.
What Problem Does This New Technology Aim to Solve?
John began by explaining the challenges that inspired the development of the new wet dust collection system. Traditional designs have been effective for high-density particulates, such as steel and stone dust. These materials, with mass densities significantly greater than water, were easier to manage with existing technology. Wet collectors have historically been effective at halting fires and addressing dust concerns for such materials.
However, low-density materials, including grains, food products, and seasonings, present unique challenges. These materials have lower settling rates and can block scrub impellers and mist eliminators. The mist generated by the high-energy movement of water in wet collectors further complicates the process. Addressing these issues required innovative solutions, particularly for materials with mass densities closer to three to five times that of water.
One of the primary difficulties lies in controlling dust particles that tend to stay suspended in mist rather than settling into the scrub tank. This issue leads to recurring maintenance challenges and potential inefficiencies in collection processes. By identifying and addressing these challenges, the team at Schubert Environmental has introduced new methods to tackle these persistent problems.
What Role Does Mist Play in Wet Dust Collection Challenges?
Mist formation is an unavoidable side effect of the wet dust collection process. High-energy water movement generates mist, which can carry fine particulates into the exhaust system. For low-density materials, the slower settling rates allow particles to become re-entrained in the mist, leading to buildup on blower wheels and reduced system efficiency over time.
To address this issue, Schubert Environmental developed a horizontal cyclone system. This patented feature captures mist and directs it back into the scrub tank, preventing particulates from reaching the blower or silencer. This innovation reduces maintenance requirements and prolongs the system’s operational life. Mist elimination is critical for maintaining efficiency, especially when dealing with low-density materials.
The mist management process does more than protect internal components; it also improves overall air quality by reducing particulate emissions. By integrating mist capture with a focus on cleanable components, the system aligns with stricter safety and environmental standards, ensuring reliability across multiple industries.
Which Materials and Applications Are Best Suited for These Systems?
The new wet dust collection systems excel with low-density materials like grains, food seasonings, and other lightweight particulates. While applications such as plastics have been explored intermittently, the primary focus remains on industries like food processing. Specific examples include mixers for seasonings, energy bars, and specialty bread or crackers. These applications often require systems capable of managing smaller volumes of air—typically between 8,000 and 12,000 cubic feet per minute (CFM).
For larger-scale operations, wet collectors face size limitations. While dry collectors remain necessary for ventilating massive facilities, wet collectors are advantageous in smaller applications where oily or sticky particulates are present. Oily dust, for instance, can clog dry collectors, making wet collection a more practical choice.
Additionally, wet collectors are particularly well-suited to scenarios where particulate material has high adhesive properties or contains oils. These systems prevent clogging and minimize fire risks compared to traditional dry collection methods. They also work effectively in environments where frequent cleaning and maintenance are necessary to meet sanitation requirements.
What Are the Key Features of the New System Design?
Several innovations make Schubert Environmental’s new systems stand out. The ability to fully disassemble and clean the system’s internal components addresses food safety and maintenance challenges. Unlike older designs with permanently installed components, the new system allows users to remove and clean scrub impellers, enhancing usability and reducing downtime.
Another important feature is the patented cassette sludge ejector. This chain-and-paddle system efficiently removes sludge and slurry from the scrub tank. In older designs, maintenance often required workers to crawl into confined spaces, posing safety risks. The cassette sludge ejector eliminates this need, as the entire assembly can be removed for servicing. This innovation not only simplifies maintenance but also aligns with safety regulations regarding confined spaces.
Additionally, the system’s horizontal cyclone significantly improves mist control. This mechanical separator minimizes mist-related issues, such as particulate buildup on blower wheels, by ensuring that mist is redirected into the scrub tank. This feature enhances the system’s performance and reduces the frequency of maintenance.
Another feature involves the integration of stainless-steel components, which ensure durability and compliance with food-grade standards. The design also includes easy access for routine cleaning, making the system suitable for applications with stringent hygiene requirements. This adaptability ensures its effectiveness in diverse industrial scenarios.
Early Success Stories
Early adopters of the new system have reported positive results. Smaller units, with capacities ranging from 8,000 to 12,000 CFM, have been particularly successful in food processing applications. Examples include facilities producing energy bars, specialty breads, and crackers. These industries benefit from the system’s stainless-steel construction and efficient sludge removal capabilities.
For larger applications, such as those requiring hoppers and pumps to manage slurry, the system provides additional flexibility. By maintaining the scrub water’s consistency and preventing concentration buildup, these systems ensure reliable performance over time. Facilities with existing water treatment capabilities can integrate the new system seamlessly, further enhancing its applicability.
One notable success story involves a food processing plant specializing in energy bars. The facility faced issues with oily dust clogging its dry collection systems. After transitioning to Schubert’s wet dust collection system, the plant reduced maintenance costs and improved production efficiency. Similar results were seen in a bakery using the system for handling fine flour and seasoning particulates.
Conclusion
Schubert Environmental’s advancements in wet dust collection systems address the unique challenges of low-density materials. By focusing on mist control, system cleanability, and safety, these innovations set a new standard for efficiency and maintenance. Industries dealing with grains, food products, and other lightweight particulates can benefit from these systems, ensuring safer and more effective operations.
As industrial requirements evolve, the adaptability of these systems positions them as a valuable solution for a wide range of applications. With continued innovation and support, Schubert Environmental is paving the way for safer, cleaner, and more efficient dust collection processes across diverse industries.
If you would like to discuss further, leave your thoughts in the comments section below. You can also reach John Schubert directly:
Website: https://replaceair.com/industrial-air-cleaning-systems/
LinkedIn: https://www.linkedin.com/in/john-schubert-007b418/
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
ReplaceAIR
Standards
NFPA 484
Download the episode
DSS290: Using Wet Dust Collection for Low-Density Materials With John Schubert
