Industrial dust extraction equipment abrasive dusts

Naaykens has extensive experience with industrial extraction systems for all kinds of production processes that release abrasive, wearing or abrasive dust.

Some examples where highly aggressive abrasive dust occurs:

Ceramic dust: Tile and brick manufacturers;
Blasting dust occurring at blasting companies;
Glass wool and stone wool dust at insulation material manufacturers;
Glass dust at recycling plants;
Slag and metallic dust at foundries;

Our designs therefore take into account the additional risks associated with abrasive, abrasive dust.

With abrasive dust, wear is (by definition) a quick problem – the hard, sharp abrasive dust can quickly cause worn-out parts if the industrial extraction system is designed incorrectly. Holes are punched in pipes, filter cartridges or valves. This wear can occur very quickly, and often the holes in the pipes cause ‘unexpected downtime’: production has to be stopped suddenly.

With our experience, we successfully apply various methods to reduce abrasive dust wear. Consider:

Appropriate piping to reduce the impact of air velocity;
Application of rubber-coated pipework;
Use of wear-resistant parts, such as hardened steel or manganese steel.

Example of an industrial abrasive dust extraction system
Grinding dust is very hard and sharp, and therefore very abrasive dust. This requires an abrasion-resistant solution.

Abrasive dust - wear due to abrasive dust

Abrasive dust is a common waste product of various industrial and manufacturing processes. It typically consists of sharp, hard particles that can cause damage to pipework and machinery.

Everyone is familiar with the abrasive action of sandpaper. Abrasive dust wears through pipework in a similar way – slowly removing the material until at some point holes appear. The consequences vary from sucking in false air to a large accumulation of dust in hard-to-reach places.

This works on the same principle how blasting cleans or roughens a surface. We have a lot of experience with this from our sister company Straaltechniek.

The abrasion is very hard and sharp, and therefore very abrasive dust. This requires an abrasion-resistant solution.

Customer request: supply of industrial extraction system for highly abrasive dust with short delivery time

An intermediate supplier we do business with came with an urgent request: a customised solution for the specific problem had to be delivered at short notice. And since the rest of the production line was to be delivered soon, an urgent delivery was highly desirable.

For a normal extractor, this is certainly not a problem, but this customer’s process resulted in highly abrasive dust, which meant another wear-resistant solution had to be provided.

Fast delivery through in-house capacity

Our in-house knowledge and flexible capacity enabled us to custom design and manufacture this industrial extraction system for abrasive dust in a very short time. This customer involved two identical machines.

Our flexible capacity and close ties with our suppliers allowed us to source critical parts well in advance to ensure delivery times. This even in a the period when every industry was struggling with very long product delivery times.

Adaptations for abrasive dust for industrial extraction plant

The engineers at Naaykens used their very extensive and up-to-date experience to design the cyclone. Because of the abrasive dust, it is lined inside with rubber, and the dispersion chamber is made of wear-resistant hardened steel. It was designed specifically to the customer’s requirements and, with suitable piping, installed as a complete industrial extraction system in time for delivery.

To our great satisfaction, when expanding their capacity a year later, the customer decided to place an order for two additional industrial extraction units in the same design.

Features industrial extraction system

Reference	Order 85645
Flow rate	Maximum: 15.000 m³/h Nominal: 10.000 m³/h
Specific requirements	Highly abrasive dust, fast delivery time, includes cyclone. Including afterfilter for blowing clean air back to factory
Filter size	Tailoring alongside designed machines
Dust type	Spring steel grinding dust – approx. 10-100 μm
Dust concentration at inlet	Maximum: 1 g/Nm³ Expected: 0.12 g/Nm³
Emission	<1 mg/Nm³

Impression of delivered industrial extraction system

In the pictures below, you can see an impression of one of our supplied installations. Here you can clearly see how the cyclone and filter are built up as an integral solution alongside the grinders.

Klik om te vergroten

Do you also have a problem with abrasive dust? We are happy to take a look and can offer you tailor-made, no-obligation advice.

Design process triple filtration abrasive dust

We would like to take you through the design process of such a cyclone. For this customer, the dust supply was relatively large, and given that the dust is blown back into the factory, the dust emission should not be high. In this case, a three-stage rocket was chosen together with our intermediate supplier:

A ‘pre-separating’ cyclone for the coarsest dust as well as the largest bulk;
An active compressed air-cleaned cartridge filter to separate the medium to fine part of the dust;
An afterfilter or police filter (think of the well-known HEPA filter) to separate the remaining fine to very fine part of the dust.

An insight into the actual calculations on emissions can be found below:

Schematic drawing

Physically built

Technical characteristics filtration per separation step
Particle size offered air	Mainly coarse to very coarse dust: Largest part >10 µm to 2 mm	Medium coarse dust after separation of coarse residues: Largest part 5-50 µm	Fine to very fine residue after main filter: Largest part: >0.4 µm
Dust load	1.200 g/h	60 g/h	0.3 g/h
Dust concentration inlet air	120 mg/nM3	6 mg/nM3	0.03 mg/nM3
Separation rate	95% for coarse dust	99.5% for medium-coarse dust	95% for fine dust
Mass flow of dust in output air	60 g/h	0.3 g/h	0.015 g/h
Dust concentration output air	6 mg/nM3	0.03 mg/nM3	0.015 mg/nM3
Expected separation and dust collection	1140 g/h	60 g/h	300 mg/h

The above plant also meets our design requirements: something best seen in how quickly the afterfilters fill up. With a dust load of 300 mg/h, after 30 weeks of operation á 40 hours a week, there should be 360 grams of dust in the afterfilters. Given we also build in our safety margins, we expected even less – which was also correct. Inspection revealed some dust in the afterfilters, but still well below the expected 360 grams.

We will gladly think with you, about the most suitable solution for you!