Design of aspiration and air cleaning systems

Nowadays absolutely all manufacturers of both consumer and heavy industries are in need of cleaning production of hazardous emissions and wastes. As a rule, a manufacturing process means air pollution with gas and dust. That’s why before the treated air reaches the atmosphere it shall be cleaned thoroughly. To clean polluted air a system of aspiration is engineered at the production lines.

Aspiration is the process of gas and dust removal which are formed in the production areas at the process of operation. Air clean systems with extended air ducts and cleaning equipment are engineered to remove dust emissions. Aspiration is one of the most difficult types of ventilation which is necessary for such many spheres as:

• Car industry
• Wood processing industry
• Metallurgy industry
• Metal working
• Food industry
• Graphic printing systems
• Tobacco industry
• Pharmaceutics
• Chemical process industry
• Paper mill industry, etc

A well engineered aspiration system is one of the key and necessary components for an effective operation of all production process.

There are two types of air cleaning systems – mono-block and modular units.

Mono-block aspiration units are the most popular systems. The advantage of such systems is the autonomous operation and portability. The units may be placed closely to the source of air pollution. Body versatility provides an easy bus connection.

Mono-block aspiration units are divided into portable and stationary systems.

Portable aspiration systems are small-sized plants to purify small amounts of air which is removed from one or two working places. They may be moved by means of wheels and are often equipped with flexible devices to collect dust directly from the pollution source. Such systems are used in limited areas or in places which are located closely to the dust emission sources, for example, welding posts.

• A mono-block aspiration system consists of the following:
• A ventilator
• Filter elements (cartridges, arms)
• A storage for filtered dust collection
• A system for pneumatic agitation of filter elements
• A controller to control purification cycles

Sets of different parts necessary for the filter plant are available depending on working conditions.

To collect polluted air from several sources simultaneously stationary aspiration systems are used. The production cost of such equipment is lower compared to portable units what is a major advantage on the market. Equipment for stationary systems may be placed at a significant distance from the pollution sources – even outside the production premises.

However, the modular aspiration system is the most efficient type. Such a system is engineered and assembled based on a detailed task which shall be thoroughly calculated.

The key elements of the modular air cleaning system:

• Low-pressure fans
• Air conduits
• Cutting modules
• Separators
• Air filters
• Presses and press-containers

The main difference between the aspiration system and other types of ventilation is the high inclination angle of air conduits to prevent from forming stagnant zones and a high speed of air flow. As the air ducts are influenced by different aggressive volatile compounds they are produced of thick metal (1,2 – 5 mm thickness) and their shaped pieces are made of metal as thicker as 1 mm against straight pieces. As the aspiration air ducts shall be often dismantled for cleaning or replacement sometimes it is not possible to use flange joints. Flange joints may become unable for dismantling. That’s why quick-disconnecting bodies are used for air ducts connection. Valves are installed to control air flow inside the air conduits.

At the process of engineering it is necessary to take into account not only the efficiency of air cleaning in the working area but also an opportunity to save heating and power expenditures. Recirculation is not always possible and when it is possible then it asks for special requirements to the level of air cleaning.

Such systems require deep knowledge and experience for qualitative engineering, assembly, maintenance, appraisal and operation.

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