News & Resources

New House Bill Demands Action on Combustible Dust

Posted on February 25, 2011 by Administrator

Rep. John Barrow, a Georgia congressman whose district includes the site of a tragic 2008 refinery explosion traced to combustible dust, has re-introduced The Worker Protection Against Combustible Dust Explosions and Fires Act (H.R. 522). The bill calls for OSHA to take swift action toward regulating combustible industrial dusts in the workplace.

The provisions of the bill state that it will:

• Streamline OSHA’s process for issuing an interim standard and direct OSHA to issue an interim final Combustible Dust standard within a year.
• Direct OSHA to issue a final standard within 18 months. OSHA would be required to include relevant parts of National Fire Protection Association standards.
• Keep the interim standard in effect until the final standard is issued.

An explosion on Feb. 7, 2008, at the Imperial Sugar Refinery in Port Wentworth, GA resulted in the deaths of 13 workers and injured many others. The U.S. Chemical Safety Board determined that combustible sugar dust was responsible for the blast.

“I visited the Imperial Sugar facility last week and saw the steps they’ve taken to improve their facility,” Rep. Barrow said. “But thousands of other factory workers around the country are at risk of a similar disaster. Other manufacturers need to improve their safety programs as well.”

Rep. Barrow previously introduced the bill in 2009, when it was approved by the House but did not reach a vote in the Senate. The congressman is hoping for a better outcome this time. See this article for more details: House Democrats propose bill requiring OSHA to set combustible dust regulations within one year

If the bill passes into law, industrial manufacturers will face a looming deadline to solve their combustible dust risks. Air Purification has the resources to make facilities compliant and keep employees safe. Contact us to learn more.

Posted in Combustible Dust, OSHA Standards | Leave a comment

Ambient Air Cleaners and Metal Dust Reclamation

Posted on December 30, 2010 by Administrator

Facilities ranging from industrial plants to shops and factories to metal refineries have become aware of ambient air cleaners as a necessity in eliminating respiratory health conditions. Typically, industrial air purifiers are most effective in capturing larger particles, allowing the smaller dust particles to escape and remain suspended in the air. Ambient air cleaners are most effective in confining these small dust particles which can cause serious health problems by permanently lodging into lung tissue.

Ambient air cleaners provide a solution to facilities dealing with dust particles and other airborne residue and are critical for operating within safety standards and regulations. Air quality is dramatically improved by the filtering of dust, smoke, coolant mist, oil smoke and other atmospheric pollutants. As the technology behind these systems advances, so does the efficacy and flexibility of installation. Ambient air cleaners are available as free-hanging, self-contained units, HVAC integrated systems, and independently ducted cleaners.

Advances in technology have also created the ability to preserve valuable metal dust that otherwise weighs on a facility’s profitability. Air Purification, Inc. offers ambient air cleaners that show what precious metal dust would have otherwise been lost. Prefilters should stay white and free from debris, yet for an average refinery these prefilters are visibly coated with a layer of metal dust in only a short period of time. Not only do these ambient air cleaners maintain pure air and eliminate the need for outside ventilation, but they also preserve your precious metal dust so that it can be reclaimed.

The video below is an ambient air cleaner installation we performed for our customer in a large precious metals melting department. The prefilters are supposed to be white and after only 2 weeks of operation you can see what was collected. This material can then be burned and reclaimed straight off the prefilters for additional profits.

Because these ambient air cleaning systems and units consistently produce consumable goods in excess of previous expectations, they pay for themselves. A certain level of purity within the air is an unavoidable necessity within metal refineries and similar factories – a level only ambient air cleaners can achieve. Investing in a system which results in recurring additional revenue is a solution that not only meets associated requirements, but becomes a consistent source of improved operations.

See Air Purification at FABTECH

Posted on October 25, 2010 by Administrator

We are pleased to announce that Air Purification, Inc. will be attending FABTECH 2010 in Atlanta, Georgia on November 2-4, 2010. FABTECH is North America’s largest and longest-running annual showcase of sheet metal forming equipment and fabricating, finishing, tube and pipe, stamping and welding equipment. This year’s event at Atlanta’s Georgia World Congress Center will be hosting an estimated 22,000 visitors and over 1,000 exhibiting companies covering more than 350,000 net square feet of floor space.

Look for Air Purification, Inc. at Booth #7725 in Welding Hall “C.” Visitors will have the opportunity to see a number of live demonstrations in our booth. Stop by to see an oil mist eliminator in operation, as well as a small dust collector and a high efficiency vacuum. Our representatives will also be discussing Air Purification’s combustible dust awareness and education initiative, aimed at helping companies comply with the latest OSHA directives to prevent dust explosions.

For an example of Air Purification’s innovative efforts in evaluating and testing welding equipment, take a look at our recent blog post titled Welding Fumes: A Case Study.

As a reminder, Air Purification, Inc. has recently stepped up our participation in social media networks in conjunction with our newly relaunched web site, so be sure to connect with us on Facebook, Twitter and LinkedIn.

We look forward to seeing you at FABTECH!

Posted in Combustible Dust, Dust Collectors, Events, Industrial Vacuums, Oil Mist Collectors, Welding Fumes | Tagged Dust Collectors, FABTECH, Idustrial Vacuums, Oil Mist Collectors | Leave a comment

A Plasma Cutting Success Story

Posted on October 5, 2010 by Administrator

A major manufacturer of truck bodied cranes had an application for plasma cutting of heavy steel plate ranging on size from ½” to 1 ½” in thickness. A dust collector was sized for the plasma table manufacturer’s recommended airflow; and because it was a new process and equipment, actual dust loading levels were estimated.

The original dust collector initially functioned well with the original filters expected to last approximately 12 months. However, when full production began after a 4-month ramp-up in production, it became evident that the filters were not sufficient to handle the extremely heavy inlet loadings. A process change to coating the bare steel with a rust preventative created a situation that finally pushed the filter life into an unacceptable range. Due to the new adhesive nature of the smoke and dust particles, the stickier particles were reducing the filter cleaning effectiveness and the filters were lasting now only 3-4 weeks.

After numerous attempts to change the media and revise the filter pulse system, the customer and API decided to replace the existing collector with a Micro Air Model RP8-4 with the Intellitouch control system. With the new system, the airflow available to the plasma table was increased from the initial 3800 CFM to 4900 CFM for better smoke scavenging. All existing table ducting and spark dropout chambers were functioning well and were retained. API removed the old collector and installed the RP8-4 with a new fabricated inlet header configuration. The equipment change-out was accomplished in approximately 1½ days, without interrupting the manufacturing production schedule.

The Intellitouch system allows the airflow to be user-adjusted for maximum efficiency, and then be held at that level as the filters load by gradually increasing the fan RPM to compensate. Target filter life for the new dust collector was a minimum of 3 months. The RP8-4 filters have lasted 8 months and are still providing the increased airflow for complete capture of the plasma smoke. Plant air quality has been greatly improved by the switch to the RP8-4 collector and unscheduled maintenance issues have been reduced to zero.

Posted in Combustible Dust | Tagged Plasma Cutting | Leave a comment

Welding Fumes: A Case Study

Posted on October 5, 2010 by Administrator

Air Purification has established a new and innovative approach to evaluating and testing new equipment as it comes on the market to ensure that we can offer our customers the most efficient and productive equipment available. Please contact us to arrange for a visit or a demonstration.

CASE STUDY: Vocational College in Eastern Tennessee

Project: Welding Department Redesign and Upgrade
Photos: See before and after photos below.
Existing equipment: Exhaust fan and canopy hoods for each weld station. Homemade grinding bench.
Problem: Students breathing zone was not protected as the weld smoke would rise to the canopy hood through the breathing zone. Not enough air flow to adequately capture weld smoke and grinding dust.

Solution: Micro Air Model RP8-2 12,000 CFM cartridge collector, 12 Airflow Systems telescoping source capture arms for each welding booth and three Airflow Systems E-Z arms for their larger work tables. One E-Z Arm installed with 10′ boom arm for reaching throughout open area in the welding lab. By using source capture arms, the students no longer have to breathe the welding fumes. Arms are positioned as needed to completely protect their breathing zone.

Additionally, three spark arrestors were installed in the duct work before the RP8-2 collector for added safety and fire protection. Exhaust from the RP8-2 collector is ducted with a “y” valve. This allows us to return the clean heated air in the wintertime to the welding lab, saving the school on heating expenses. This valve also allows us to keep the air outside during the summer months. In addition to the weld smoke system, Air Purification, Inc. also installed an Airflow Systems downdraft table for their grinding applications. The downdraft table is split in half with a dividing wall, allowing two students to grind at the same time on the same table.

This complete system will keep the welding lab safer and looking new and clean. All equipment used in this school is heavy duty industrial air cleaning equipment. Their students are now being exposed to the same equipment they will be using in a welding position.

Before & After photos

Before	After
After	After

Posted in Downdraft Tables, Testing Lab, Welding Fumes | Tagged Downdraft Tables, Weld Smoke Systems | 1 Comment

Air Pollution Control Testing Lab

Posted on October 5, 2010 by Administrator

Demonstrate the latest dust collectors
Test for removal of various dusts & fumes
Test filter media for your applications
Hands-on training for your employees

Our new testing lab is the largest industrial indoor air pollution testing lab in the southeast. It allows us to test dust collectors against various types of smokes and dusts, test different types of filter media for efficiency, and offer customers a chance to see live demonstrations of equipment to assist them in their decision making process.

All our customers are invited to visit our facility in Raleigh, NC and view live demos or send their employees to hands-on training sessions to gain firsthand knowledge of the products and their capabilities. Our plans for the lab include adding the capability to do live streaming video demos for those customers who are unable to come visit us in Raleigh.

We will continually be adding equipment to the lab to ensure that our customers have access to the best equipment to meet their unique needs. Please contact us to arrange for a visit or a demonstration!

Posted in Testing Lab | Leave a comment

Motor/Blower Energy Savings Formula

Posted on October 5, 2010 by Administrator

Proper selection of an air filtration system’s motor/blower can have an immediate and significant positive effect on the unit’s operating efficiency and energy consumption.

Blower selection, use of high-efficiency backward incline blowers, low pressure drop-type units, and proper duct velocity all determine the level of motor horsepower required.

Careful consideration of these factors can often reduce the level of horsepower actually required. The following formula can be used to calculate these factors, and the potential savings from using a smaller sized motor.

E = Electrical cost to operate one horsepower for one shift per year.

R = Cost of electricity at 10¢ per kilowatt hour (kWh). If you know your actual rate, use ratio from 10¢. For example, if your rate is 9¢, multiply your answer by 0.9; if your rate is 12¢, multiply your answer by 1.2.

C = Conversion of kilowatt hours (kWh) to horsepower (HP). (a constant)

O = Hours per year you are operating the motor. For example, one shift equals 40 hours per week multiplied by 52 weeks per year, equals 2080 hours per year.

μ = Efficiency of Energy Policy Act (EPAct) motors assumed to be 90%. Typical values are 82.5% (1 HP), 87.5% (3 HP), and 89.5% (10 HP).

T = Total cost to operate 1 HP for one year for single shift operations. If comparing a 3 HP unit to a 5 HP unit, the difference is 2 HP, so multiply the answer by 2 for the energy cost savings.

Yearly Motor Electrical Costs

Usage (Hours / Day)
HP	8	10	12	16	20	24
1	$172	$216	$259	$345	$431	$517
1.5	$259	$323	$388	$517	$647	$776
2	$345	$431	$517	$690	$862	$1,034
3	$517	$647	$776	$1,034	$1,293	$1,552
5	$862	$1,078	$1,293	$1,724	$2,155	$2,586
7.5	$1,293	$1,616	$1,940	$2,586	$3,233	$3,879
10	$1,724	$2,155	$2,586	$3,448	$4,310	$5,172
15	$2,586	$3,233	$3,879	$572	$6,465	$7,758
20	$3,448	$4,310	$5,172	$6,896	$8,620	$10,345
25	$4,310	$5,388	$6,465	$8,620	$10,776	$12,931
30	$5,172	$6,465	$7,758	$10,345	$12,931	$15,517
40	$6,896	$8,620	$10,345	$13,793	$17,241	$20,689

Posted in Energy Savings | Leave a comment

Hexavalent Chromium Risk

Posted on October 5, 2010 by Administrator

Does your facility have hexavalent chromium dust, mist, or fumes in the air? Don’t say no too quickly! The Occupational Safety and Health Administration (OSHA) has issued more stringent safety and health rules for businesses to comply with hexavalent chromium, or Cr(VI), requirements. The new standards reduce the permissible exposure limits by more than 90 percent. To protect your workers, reduce your liability and remain in compliance, you need to be familiar with these new OSHA standards and the causes and effects of chromium dust.

Many production processes at industrial companies, construction companies and shipyards result in chromium dust particles being released into the air. Hexavalent chromium compounds are widely used in the chemical industry as ingredients and catalysts in pigments for dyes, paints, inks, and plastics; in chromates added as anti-corrosive agents to paints, primers, and other surface coatings; and in chromic acid electroplating. Cr(VI) can also be produced when welding on stainless steel or chromium painted surfaces.

You may not even be aware of this health hazard in your facility because you may not be directly using chromium hexavalent compounds in your production. But if you do contract work on materials, parts and components provided to you by other companies then you might be producing chromium hexavalent dust particles, thus falling under the new and more rigorous OSHA guidelines.

Hexavalent chromium dust, mist or fumes can contaminate hands, clothing, beards, food and beverages, and the long-term health effects can be serious. The primary means of human exposure to hexavalent chromium and chromate salts are inhalation, ingestion and skin contact. Hexavalent chromium is considered a potential lung carcinogen and long-term health effects can include lung cancer, asthma, nasal ulceration and even perforation of the septum (the wall separating the nasal passages), as well as skin dermatitis and ulcerations. Affected organs can include the respiratory system, liver, kidneys, eyes and skin. For your company, this is a hazard and a potential liability that needs to be addressed.

The preferred approach to managing this air quality hazard is to use engineering controls such as proper ventilation or equipment and process modification. Air Purification, Inc. can help your company meet and exceed the new OSHA rules. Please contact us today to discuss this issue and to learn methods of indoor air quality improvement, total facility ambient air filtration, source capture methods, and blow off decontamination to remove airborne contaminants at the source.

Energy Savings with VFD Systems

Posted on October 5, 2010 by Administrator

Are you looking for big savings on energy and filter replacement? The Intelli-Touch control panel for use with Micro Air dust collection systems is truly a state of the art system enabling the dust collector to always operate at the designed CFM. It reduces energy consumption with a built-in variable frequency drive (VFD) that automatically controls motor RPM based on CFM needed at the running static pressure.

The Intelli-Touch also utilizes a soft start and ramp up of motor speed which eliminates sudden surges of power usage, further reducing energy requirements. All settings are controlled easily at the touchscreen. By operating at the exact specifications your application requires, there is no wasted horsepower, compressed air, or energy. It also allows for the maximum possible filter life, and built-in monitors give alerts for filter change-out.

The patent-pending control panel regulates airflow on an as-needed basis, providing dramatic energy savings, filter cleaning on demand reduces compressed air requirements and the capability of regulating airflow through branch pickups without the use of traditional blast gates and variable frequency drives.

Use the online calculator at http://www.microaironline.com/intellitouch/energy_savings.php to see how much the Intelli-Touch system can save your operation.

Posted in Energy Savings | Tagged Dust Collectors, VFD Systems | Leave a comment

Is My Dust Combustible?

Posted on October 5, 2010 by Administrator

When looking to protect your equipment against a dust explosion, it is critical to know the Kst value of your material. Kst is the dust deflagration index, and it measures the relative explosion severity compared to other dusts. This is a relative index, however, and any material with a Kst value greater than zero is considered to be at risk of an explosion. Other than silicon or sand, every kind of dust is potentially combustible to some degree.

Examples of Kst Values for Different Types of Dusts

Dust explosion class*	Kst (bar.m/s)*	Characteristic*	Typical material**
St 0	0	No explosion	Silica
St 1	>0 and ≤00	Weak explosion	Powdered milk, charcoal, sulfur, sugar, zinc
St 2	>200 and ≤200	Strong explosion	Cellulose, wood flour, polymethyl acrylate
St 3	>300	Very strong explosion	Anthraquinone, aluminum, magnesium

The actual class is sample specific and will depend on varying characteristics of the material such as particle size or moisture. Source: http://www.osha.gov/Publications/3371combustible-dust.pdf * OSHA CPL 03-00-008 – Combustible Dust National Emphasis Program. ** NFPA 68, Standard on Explosion Prevention by Deflagration Venting.

Kst Values for Common Dusts:

Any value greater than zero is a potential explosion risk

Dust	KSt Value	Characteristic
Activated carbon	44	Weak Explosion
Aluminum grit	100	Weak Explosion
Aluminum powder	400	Very Strong Explosion
Asphalt	117	Weak Explosion
Barley grain dust	240	Strong Explosion
Bronze	31	Weak Explosion
Brown coal	123	Weak Explosion
Calcium stearate	132	Weak Explosion
Cellulose pulp	62	Weak Explosion
Cellulose	229	Strong Explosion
Corn	75	Weak Explosion
Charcoal	117	Weak Explosion
Cotton	24	Weak Explosion
Dextrin	106	Weak Explosion
Egg White	38	Weak Explosion
Epoxy powder	125	Weak Explosion
Epoxy resin	129	Weak Explosion
Flour, Bakers 4.3% Moist	112	Weak Explosion
Lead stearate	152	Weak Explosion
Magnesium	508	Very Strong Explosion
Malt dust	122	Weak Explosion
Melamine resin	110	Weak Explosion
Methyl cellulose	209	Strong Explosion
Milk powder	90	Weak Explosion
Paper tissue dust	52	Weak Explosion
Para formaldehyde	178	Weak Explosion
Peat	178	Weak Explosion
Pectin	162	Weak Explosion
Phenolic resin	129	Weak Explosion
Polyester	85	Weak Explosion
Polyethylene	134	Weak Explosion
Polyurethane	156	Weak Explosion
Rice starch	190	Weak Explosion
Silicon	126	Weak Explosion
Soap	111	Weak Explosion
Sodium ascorbate	119	Weak Explosion
Sodium stearate	123	Weak Explosion
Soot	26	Weak Explosion
Soybean flour	110	Weak Explosion
Starch, corn	202	Strong Explosion
Sugar	138	Weak Explosion
Sulfur	151	Weak Explosion
Tobacco	12	Weak Explosion
Toner	145	Weak Explosion
Wood dust	102	Weak Explosion
Wood Flour	205	Strong Explosion
Zinc	176	Weak Explosion

Posted in Combustible Dust | Tagged Kst Values | 1 Comment

News & Resources

New House Bill Demands Action on Combustible Dust

Ambient Air Cleaners and Metal Dust Reclamation

See Air Purification at FABTECH

A Plasma Cutting Success Story

Welding Fumes: A Case Study

CASE STUDY: Vocational College in Eastern Tennessee

Before & After photos

Air Pollution Control Testing Lab

Motor/Blower Energy Savings Formula

Yearly Motor Electrical Costs

Hexavalent Chromium Risk

Recommended Links:

Energy Savings with VFD Systems

Is My Dust Combustible?

Examples of Kst Values for Different Types of Dusts

Kst Values for Common Dusts:

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