A Canadian aerospace company was looking to upgrade its dust collection systems used in high-velocity oxygen fuel (HVOF) coating, blasting, and grinding processes. These operations generate combustible dust, which poses serious safety risks if not properly managed.
The original plan was to retrofit five aging dust collectors during a four-week shutdown to meet NFPA standards. However, Wayne Zimmer, the regional manager at Camfil Air Pollution Control, advised against this approach. Instead, he recommended purchasing new dust collectors, explaining that retrofitting comes with hidden dangers and unnecessary costs.
Camfil APC avoids retrofitting for several reasons:
- **High Costs**: Retrofitting often involves expensive engineering work that doesn’t necessarily fix the underlying issues of old equipment.
- **Operational Risks**: Assessing the structural integrity of aged metal can be difficult, increasing the chance of future failures.
Zimmer and his team suggested a new dust collector from Camfil APC, which offered a faster, more reliable installation. The client evaluated the options and ultimately decided to go with Camfil’s solution. Three years later, the system is still running smoothly without any filter replacements or operational issues. The company is now planning to replace all its remaining outdated dust collectors with NFPA-compliant systems.
**Watch the Full Switching Story**
To learn more about how this company made the switch, watch Camfil APC’s Wayne Zimmer in this video.
**Dangers of Combustible Dust**
Combustible dust is a major hazard in many manufacturing environments. It's created during processes involving materials like paper, rubber, sugar, aluminum, magnesium, wood, chemicals, and textiles. In the aerospace industry, HVOF spraying, blasting, and grinding are common sources of such dust.
When suspended in the air, these fine particles can ignite and explode when exposed to an ignition source—like static electricity, friction, or open flames. These incidents can cause severe damage to equipment, facilities, and even lead to injuries or fatalities.
According to DustEx Research Ltd., between January 1 and July 1, 2023, there were 159 fires, 32 explosions, 71 injuries, and 48 deaths worldwide due to combustible dust. In the U.S., an average of 28.4 combustible dust explosions occurred annually between 2016 and 2023, resulting in 28 injuries and 3.5 fatalities each year.
To reduce these risks, manufacturers must implement effective dust control measures, including properly designed dust collection systems with explosion protection.
**Is Your Dust Combustible?**
Determining whether your dust is combustible is crucial for selecting the right dust collection system. An accredited testing lab can analyze your dust and determine its explosibility using standards like NFPA or ASTM. One key metric used is the Kst value, which measures how explosive a dust cloud is.
For example, magnesium has a Kst of 508, making it extremely explosive, while charcoal has a Kst of 10, indicating it’s not explosive. Understanding this value helps in designing the appropriate explosion protection system.
**Which Dust Collector?**
Not all dust collectors are suitable for handling combustible dust. A poorly designed system can actually increase the risk of explosions by allowing dust to accumulate in enclosed spaces.
Camfil’s Gold Series industrial dust collectors are engineered to safely remove toxic and combustible dusts and fumes. They include advanced explosion protection systems that meet or exceed NFPA and ATEX requirements, helping to protect workers and facilities from both exposure and potential explosions.
Click here to watch a short video about the Gold Series collector.
If you're unsure about your dust type or need help choosing the right system, contact Camfil’s dust collection experts. They can assess your facility and recommend the best solution to manage combustible dust and keep your workplace safe.
Find out more about our products and why so many companies trust Camfil to design and build their complete dust collection systems.
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