DeDuster Anthology The Complete Guide
DeDuster Anthology The Complete Guide
Following Natures Lead
Purity of material was the driving force behind the development of separation technologies. It began thousands of years ago with the need to clean grain, corn, rice and other foods, a task that was accomplished with the aid of a simple stream of air. Over the centuries, the desire for efficiency resulted in new inventions all designed to improve the cleaning and separation processes. Our modern day machine cleaning technology is based on this same concept of separation with air.
Product inlet
Air and fines outlet
In order to build an understanding of the technology of cleaning or dedusting materials, let us first take a look at history. After the most basic cleaning method of simply tossing the material into the air and letting air and gravity do the work, the need to improve efciency resulted in other innovations. The scalperator was a separation machine that removed hulls from grains. Later, the aspirator was used. Its cleaning principle is based on air blowing perpendicular to the material flow. This was an efficiency improvement, one that is still useful in industries with lower cleaning efficiency requirements like agriculture, among others. The requirement for higher cleaning efficiency continued and, in the 1970s and 1980s, the plastics industry began to drive demand. The need for better quality resulted in the development of the elutriator. This technology was focused on the cleaning of pellets at the end of a dilute phase conveying line. Because of its working principle, an elutriator was typically installed on top of a silo or before a silo farm, where the distribution of pellets to the storage silos is done after cleaning. Because its principal of cleaning is based on counterflow, the elutriator does not remove long streamers, also called angel hair, so it was often combined with a drum sieve. The graphics on the next page illustrate the counterflow principle and a typical elutriator installation at a silo farm.
Air inlet Product outlet (heavy materials)
Scalperator
Air and fines out
Product inlet
Air in
Air in
Air in
Air in
Product outlet (heavy materials)
Aspirator
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DeDuster Anthology The Complete Guide
Einlauf fr Pellets und Frderluft
Elutriator System
Dusty air outlet Pellet acceleration Cleaning zone by counterflow air
System with Elutriator
Cleaning air inlet
Detail
Many more separation and cleaning machines were marketed to address specific application requirements. There were separators with bottom entry and separators with rotating discs, among others. As efciency demands increased, the dedusting technology emerged as a solution that provided superior results when cleaning all kinds of bulk solid materials. As technology evolved further, the Pelletron DeDuster emerged as the most efficient way to remove all kinds of dust, streamers and other contaminants. For a better understanding of fines creation and modern fines removal, let us take a closer look.
Elutriator
Product outlet Rotary Valve
Where Do Fines Come From and Why Is Cleaning So Important?
Some dust and contaminants occur naturally in products like minerals, food, tablets and other bulk solids, while others are caused by the way the products are handled. Impurities in plastic pellets, both fines (dust) and angel hair (streamers), are generated by the friction in conveying lines. Dilute phase systems create large amounts of dust and streamers; the higher the velocity, the larger the amount of impurities. Pipe elbows also cause friction and result in the creation of more dust and streamers. The high pressure in dense phase, or slow motion systems, creates very fine dust due to wall friction and friction between pellets. Temperature, pellet shape and product characteristics can also contribute to the creation of dust. Cleaning bulk solids is important for a number of reasons. Food and pharmaceutical bulk solids are cleaned for hygienic reasons and to improve the quality of the finished, packaged product. Minerals are cleaned primarily to avoid environmental and health problems. The plastics industry cleans pellets to improve the quality of both the pellets and the nished plastic product.
The Pelletron DeDuster The Ultimate Cleaning Technology
The Pelletron DeDuster was developed as a result of demands for high quality standards in the plastics industry, but the technology can be used for all kinds of granular bulk materials. The list of requirements for a new, universal dedusting machine was long:
Einlauf staubiges Produkt
Remove dust and streamers with one machine Separate and remove electro-statically charged dust particles Fit on injection molding machines Offer low construction height Fit on top of extruders and under silos Reduce remaining dust level after cleaning to <50PPM To address this list of requirements, Pelletron developed a cleaning machine that combines a variety of air wash principles, plus the revolutionary electro-static flux field feature, and built it with the lowest possible construction height. When charged particles enter into the Magnetic Flux Field, the result ing Lorentz Force weakens the electro-static bond between fine dust and plastic pellets. This weakening, in combination with the air flow, allows the microfine particles attracted to the pellet surfaces to be removed.
Ausblas staubige Luft
Air in By pass air Air in
Air in
Clean pellet outlet
The Pelletron DeDuster
The specially designed slot and hole pattern in the air wash deck creates a fluidization effect, another advantage of the Pelletron DeDuster. For removing large particles and streamers, an adjustable Venturi Zone was designed. Adjustment of the Venturi Zone width, in combination with the regulation of the bypass airflow, allows a perfect separation of streamers from good product. This special air wash effect also removes the heavier particles such as paper, metal parts < 300 micron and other contaminants. The airflow in the DeDuster creates negative pressure at the DeDuster outlet. All DeDuster systems are equipped with a window made of either polycarbonate or glass. Optionally, a stainless steel door with windows can be supplied for high temperature applications. The DeDuster can also be operated in inert gas environments such as N2-systems. In situations where a DeDuster is installed before or after a conveying system, the DeDuster inlet or outlet needs to be separated by a rotary valve.
P-Series DeDuster, showing air wash deck and Venturi Zone
Research & Development and Test Facilities
Pelletron maintains a test lab to provide free-of-charge cleaning tests and detailed digital test reports for customers worldwide. There are two wet test methods established in the market, the European FEM 2482 method and the ASTM Standard D-7486-08. The FEM procedure defines dust content in three classes: Type A from 63m to 500m, Type B from 45m to 500m and Type C from 20m to 500m. The newer ASTM Standard defines the wet test measuring of dust particles from 1.6m to 500m. Pelletron recommends the use of the ASTM Standard because it covers the entire dust spectrum, including the microne dust produced in dense phase systems. For the exact measurement of the dust particles, Pelletron developed the wet test device, tradenamed FineAlyzer. Continuous testing has helped to refine customer requirements and has led research and development efforts to the creation of the X-Series DeDuster and the round RC-Series DeDuster. These new DeDuster models were targeted at applications that required lower construction height and reduced consumption of cleaning air. Pelletron believes that creativity is an integral part of the innovation process. Our engineering and design staffs are all involved in the strategic, creative development of new products. Pelletron understands that every process is different because parameters often vary considerably. In many cases, a ready-made solution is not possible. In close cooperation with our customers, we are able to find the best solution through lab testing in order to achieve the ideal process under their pre-dened conditions. An example of the Pelletron creativity is the development of the mobile DeDuster system for installation on top of bagging machines. This solution provides the highest exibility in a silo farm with packing requirements. A 3D drawing of such a mobile unit is shown on page 7.
DeDuster Anthology The Complete Guide
Dusty product inlet
Dusty air outlet
Clean air inlet Clean pellet outlet
3D model of RC DeDuster
RC DeDuster test
Flow diagram FineAlyzer
DeDuster in the test lab
Wet test for pellet cleaning
Dust in beaker
DeDuster Applications for the Plastics Processing Industry
Production of high quality end products requires clean plastic pellets. Dust and streamers in plastic pellets cause many problems for the plastics processing industry:
High scrap rates from fines burning in mold Blurry surfaces resulting from vaporized dust particles Weak spots in fibers Flaws in wire insulation Gels in films Housekeeping problems caused by dust and streamers Crusting of feed throat of screw Reduced mold and screw life resulting from carbonization of dust Mold vents clogged by dust Equipment and machines clogged by streamers Dust accumulation on silo walls, roofs and hopper walls A DeDuster can be installed directly on top of an injection molding machine or on a dryer, depending on the process requirements. The standard installation is a closed loop conguration with a fan and a dust collector. The removed dust is separated by the dust collector and dropped into a dust bucket, and the cleaned air is returned to the DeDuster. Special congurations for clean room applications are also available. Regrind is also common in the plastics processing industry. Regrind is very dusty and needs to be cleaned before it is mixed with virgin pellets, before packaging into big bags or re-pelletizing.
P1-DeDuster installed on
Before
After
Problems caused by dust
High quality end product
injection molding machine (IMM)
P1-DeDuster
DeDuster Anthology The Complete Guide
DeDuster Applications for the Plastics Manufacturing and Compounding Industry
Clean pellets, without dust or streamers, are the goal of every plastic manufacturing company. The most effective use of a DeDuster is to position it under storage silos, for use before packaging. Installation at this position allows for the efcient removal of any dust and streamers that have accumulated in the silos, including the impurities created by dust surges.
Many existing pneumatic conveying systems are equipped with older technology dust removal systems, such as scalperators, aspirators and elutriators. These systems cannot provide the cleaning results required by modern manufacturing plants. For most applications, a Pelletron DeDuster can be added under silos, before packaging, to improve the results. Pelletron has developed models that fit on bagging machines or can be moved between silos where a silo farm is in use. Because of its ability to remove the microfine, high electrostatically charged dust particles characteristic of dense phase systems, retrofitting existing systems with a DeDuster has become common practice. The flow sheet below shows examples of various solutions for the installation of DeDuster systems under silos.
3D model of mobile DeDuster installed on bagging machine
DeDuster in operation
Mobile DeDuster in silo farm
DeDuster installation solutions
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Systems Congurations
Open loop dedusting system with cyclone
An open loop system is recommended for processes with frequent product changes or for lines with frequent color changes in order to avoid cross contamination. Filtered fresh air is pushed from a wash air fan into the DeDuster supplying the cleaning air. A second exhaust air fan pulls the dusty air into a cyclone or baghouse dust collector. The dust is separated in a dust collector and dropped into the dust container. The cleaned air is then released into the atmosphere.
A closed loop system is recommended for standard operations with the same or similar product grades or for inert gas applications. A push/pull wash air fan supplies the wash air and pushes it into the DeDuster. The dust is separated by the baghouse dust collector and dropped into a dust container. The cleaned air is returned to the fan.
Open loop dedusting system with baghouse filter
DeDuster Anthology The Complete Guide
Closed loop dedusting system with cyclone CCD-system (patented)
As an alternative to a baghouse, there are also Compact Cyclonic DeDuster (CCD) systems available, a closed loop application solution with a cyclone and an inline filter. The dust is separated by the cyclone and dropped into a dust container. Remaining fine particles are separated using an inline filter. The cleaned air is returned to the fan.
DeDuster systems are available in open loop and closed loop versions, as well as in configurations for air tight systems with inert gas or clean room applications. Wash down ver sions for wet cleaning are also available upon request.
Closed loop dedusting system with baghouse filter
Selecting the Right Dedusting System
To aid in the selection of the best dedusting solution, a free-of-charge dedusting test at the Pelletron test lab is suggested. Once the type and quantity of nes present is determined, a suitable DeDuster conguration can be recom mended. For the very ne dust created in dense phase systems or for high dust volumes, a dust collector with bags is usually the best solution. For systems with coarse dust, typical after dilute phase or regrind operations, a cyclone with an inline lter is the preferred technology. For systems with high streamer content, a cyclone is usually the recommended selection. As a result of testing of over 3,000 kinds of bulk material, Pelletron has the experience to select the proper system conguration to meet any customer requirements.
One of the most important design considerations for a dedusting system is the selection of the fans. Fan sizing is affected by the length, diameter and number of elbows in the duct work, the pressure loss due to filters in the system and the pressure loss and air volume requirements of the DeDuster. Pelletron engineers take these variables and the properties of the material to be cleaned into consideration when determin ing the air volume and pressure needed for the best cleaning results. The manual solution for the air management of a fan is the use of mechanically operated dampers. These dampers are adjusted at start-up and can be readjusted easily in case of product changes. Pelletron also offers variable speed drives for fans which can be operated and regulated from a remote control station. These drives allow for proper system balance and affect energy consumption giving the end-user the ability to manage costs.
Fan with manual damper
HEPA-Filter with door open
Some applications require the use of HEPA-lters, in conjunction with the standard system conguration. Because of the high pressure loss of these lters, the design and selection of the fan(s) becomes even more critical. HEPA-lters are used in clean room applications or for the dedusting of plastic pellets for use in the electronic and optical industries.
Fans, bag house and cyclones for a dedusting system
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DeDuster Anthology The Complete Guide
How Versatile is the DeDuster?
Pelletron has developed several solutions to address unique customer applications. Besides the cleaning of plastic pellets, the DeDuster can be used for cleaning dry bulk solids in the food, mineral and pharmaceutical industries. Some examples for materials that require cleaning are:
Rice, corn, peanuts, coffee beans Iron ore, special sand, wood pellets Tablets, pills And many more
Removal of dust is often necessary because of the environmental challenge it creates. Pelletron developed a special, wear-resistant DeDuster for cleaning iron ore to address the health concerns associated with iron ore dust in the air and to save energy by reducing the dust that hinders the melting process. Our standard DeDuster systems have capacities ranging from a few pounds (kilograms) up to 200,000lbs (100 tons). For applications that require higher capacities, Pelletron has built custom models capable of processing several hundred tons per hour. For installations with inclined silo outlet pipes, the OS-DeDuster (OffSet) was developed. For narrow pack aging lines, the DO-DeDuster (single inlet and Dual Outlet) was designed. Pelletron also provides wash down DeDuster systems designed for cleaning with water between product changes. Pelletron continues to respond to customer requests for unique applications.
DeDuster for cleaning iron ore pellets
Fan for iron ore cleaning
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P400 to P2000 are equipped with double wash decks
XP15 to XP900 are equipped with double wash decks
DeDustersseries
P-Series DeDuster Original low height design
DeDuster type P5 P1 capacity range in lbs/h 100 50 600 150 in kg/h
XP-Series DeDuster X-tra low heigh & energy consumption
DeDuster type XP5 XP15 capacity range in lbs/h 650 1,000 1,100 3,500 in kg/h 300 600 500 1.600
20 250 50
P10
P2000
P1200
P800
P600
P400
P200
P120
P80
P50
P30
3,000 8,000 5,000
1,000
500
3,500 9,000 5,500
1,200
60,000 80,000
40,000
20,000
12,000
22,000 65,000 45,000
14,000
2.300 3.500 5.500
1.500
600
120,000 220,000
130,000
90,000
18.000 36.000 54.000 27.000
9.000
100.000
4.000 10.000 6.500
2.500
1.600
600
300
75
60.000
40.000
30.000
20.000
XP180 XP360
XP90
XP45
20,000 60,000
12,000
8,000
22,000 45,000
11,000
3.500 9.000 27.000 5.500
20.000 40.000
10.000
5.000
XP900
XP720
XP540
120,000 180,000 150,000 220,000
80,000 130,000
90,000
36.000 54.000 70.000
100.000
60.000 80.000
Note: Selection of the DeDuster model depends on the bulk density of the product being cleaned, the shape of the pellets and the type and quantity of the fines.
P10 to P200 are equipped with single wash decks
P1 and P5 include an agitator for dosing and regrind discharge
XP5 is equipped with a single wash deck
Wash Down DeDuster
This design is based on a standard XP-design for wash down applications. The design allows the cleaning with water and easy access to all areas of the DeDuster.
Wide Body Design
For some retrofit applications, the available height is not sufcient for the installation of a standard DeDuster. Pelletron offers a wide body version of its P and XP-series in order to reduce the construction height.
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DeDuster Anthology The Complete Guide
RC-Series
This low height DeDuster is designed for a wide range of products with capacity ranges from 10 lbs/hr (5 kg/hr) up to 100 lbs/hr (350 kg/hr). The round design allows for a reduction in height and lower energy consumption. Larger sizes are available upon request.
OS-Series
This DeDuster has an offset inlet outlet design. It can be used for applications with inclined piping or other congurations that require an offset design. Various sizes are available. Others can be designed based on unique customer requirements.
DO-Series
This DeDuster has a single inlet and a dual outlet. It can be used for applications where narrow or shallow packaging machines are installed or for other congurations that require a dual design. Various sizes are available and others can be designed based on unique customer requirements.
Polished DeDuster
For special high grade resins, mirror polishing of the DeDuster is required (bufng 400). All DeDuster types can be supplied in polished versions.
Mobile DeDuster Systems
Any DeDuster system can be supplied as mobile unit. Mobile units can be installed on rails, on a mobile stand or installed on a bagging machine.
Wear Resistant DeDuster
For high abrasive bulk materials, a wear resistant DeDuster is necessary. All DeDuster types can be supplied in wear resistant versions.
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Pelletron in Lancaster, Pennsylvania
Pelletron History
Pelletron Corporation was founded by Jerry Paulson in 1987 to address the need for a dust removal system to aid in the plastic manufacturing process. The concept, nurtured in the garage of his home in Lancaster County, Pennsylvania, was based on kinetic energy and its effect on granules as they pass through the pneumatic conveying systems that are a common part of the production process. Paulsons solution, the Kinetic Gravity DeDuster, used a magnetic flux field to disrupt the electrostatic charge between contaminants and pellets, and a patented air wash deck to separate and remove those contaminants. The dedusting process improved product quality, saved production time and reduced scrap.
Jerry Paulson
The first DeDuster from 1987.
In 2003, the company began to expand into the pneumatic conveying field. In 2010, pelletroneurope was established in Bodnegg, Germany, to better address the needs of the global market. The company continues to develop and patent various new DeDuster systems, components and conveying technologies, and today is a well-established supplier for pneumatic conveying systems and components in the dry bulk handling industry. Pelletron Corporations highly experienced Bulkmatology team has many years of knowledge in designing and building systems that meet the unique and individual needs of customers in a variety of industries. Today, in addition to dedusting systems Pelletron, and its network of representatives, offers a full range of pneumatic conveying products and services to customers world-wide.
pelletroneurope in Bodnegg, Germany
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Pelletron DeDuster Systems are Installed All Over the World
DeDuster Anthology The Complete Guide
Pelletron Headquarters
Pelletron has supplied more than 2,000 DeDuster systems to companies in more than 50 countries. It is a common practice today for plastics manufacturing companies and compounders to replace scalperators, aspirators, elutriators, drum sieves and other types of dust removal devices with DeDuster systems. Pelletron can retrofit solutions for most any type of system configuration due to the wide range of DeDuster types available. The DeDuster is also the most chosen dust removal system when new plants are designed and built. Plastics processing customers use the small P1 and P5 DeDuster as the standard equipment for installation on top of injection molding machines or dryers. Many sheet extrusion suppliers
made the DeDuster standard equipment for dust removal installed on top of extruders. Many plastic recycling plants selected the DeDuster as the most efficient and economical dust removal machine. Mineral processors have identified the DeDuster as the best machine on the market to remove dust. The special wear resistant DeDuster type can be used for cleaning of specialty sand, iron ore and other abrasive minerals including glass filled plastic pellets. Pharmaceutical customers have also selected the DeDuster as the most efcient method for cleaning tablets. Whenever high quality end products are the goal, customers around the world choose the Pelletron DeDuster to maximize success.
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Its clean
Pelletron Corporation Corporate Headquarters 1866 Colonial Village Lane Lancaster, PA 17601 USA t +1.717.293.4008 f +1.717.293.4011 www.pelletroncorp.com [email protected] Pelletroneurope GmbH European Headquarters Ahornstrae 28 88285 Bodnegg Germany t +49(0)7520.95662-0 f +49(0)7520.95662-15 www.pelletroneurope.com [email protected]
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