Misting systems for dust suppression in the production of ceramics, glass and building materials
In the production of ceramic products and building materials, a large amount of bulk raw materials is used, which is a source of dusting during transportation of unloading and loading. During the processing and processing of cullet, gypsum and ceramic products, a significant amount of abrasive dust is released into the air.
This leads to a critical general sanitary state of the environment, the productivity of personnel decreases due to the resulting diseases and occupational diseases of workers.The elimination of dust that settles on production equipment, clothing, machinery and aggregates and hovers in the air is simply mandatory, since it leads to damage and breakdown of these material values, which reduces the profitability of production.
In the production of concrete and ceramic products, a large number of different bulk materials are used — concrete, gypsum, clinker, dolomite. And all these materials are gathering dust during loading, unloading and transportation. Dust pollutes work equipment, machinery, workwear, lighting and heating devices in industrial and warehouse premises.
For localization or complete suppression of dust, high-pressure fog generation systems are suitable. Dust particles "overgrow" with small drops of water from the fog, get heavier and fall to the floor.
Also, for the normal maturation of concrete products (hydration), it is necessary to maintain high humidity in the steaming chamber. This will preserve the water already present in the concrete. High-pressure misting systems can quickly raise the humidity to 90-100% with little cost of electricity. Depending on the size of the chamber and the amount of water sprayed, the evaporation of 1 kg of water will require from 0.01 to 0.004 kWh of electricity. Thanks to the droplet size of about 10 microns, fog jets will not erode concrete products, unlike low-pressure fog systems.
There are two approaches to dust suppression — complete fog coverage of the dusting zone by creating a moistened surface on dusting materials or creating a fog curtain around the dusting zone. Which approach to choose depends on technological restrictions on the moisture content of bulk materials.
building materials solves important tasks:
1. Humidified and cooled air is a healthier mucous membrane and stronger immunity for working personnel, comfortable working conditions thanks to a decrease in temperature in the workshop, where glass melts, ceramic tiles bake and thermal drying of gypsum or cement—containing products.
2. Productivity growth – the productivity of the staff increases, the percentage of morbidity caused by harmful working conditions decreases.
3. A healthier production atmosphere – fatigue decreases, attentiveness increases, the factor of industrial injuries - caused by the concentration of dust in the air - decreases.
4. Reduction of harmful dust is due to the effect of dust suppression inherent in the operation of the systems, which captures floating dust and substances in the air.
5. A cost–effective solution - if we take it in comparison with industrial aspiration systems..
6. Increase in profitability — increase in income due to optimization of production processes. Reducing the cost of repair equipment and its technical prevention.
High pressure misting systems have a number of advantages:
§ Low specific consumption of electrical energy;
§ Uniform humidification and dust suppression throughout the room;
§ Possibility of installation of a system of pipelines and injectors according to wishes;
§ Easy installation of the fog system without the use of special tools;
§ The ability to deal with dust sources localized from the processes of processing and processing of materials;
§ There was a system cost recovery.
The device of the high-pressure fog formation system
The system of pipelines and injectors is easily assembled and mounted, the pipelines are connected by collet clamps, without the use of special tools. This allows you to assemble a humidification system according to the individual dimensions of the customer.
Using nozzles of different dimensions, shapes, type of spraying and performance, with holes of different diameters, it is possible to choose a mist for dust particles of any size and any working conditions.It is possible to install nozzles on rotary hinges to change the direction of the jet, as well as with water pressure adjustment, also to change the trajectory of the jet. All nozzles of this installation must be the same size to generate fog drops of the same size.
The nozzles can be made of latunium or stainless steel, easily dismantled and cleaned with a simple tool. The use of steel reduces wear and corrosion and ensures years of maintenance-free operation even when using poor quality water.
Stationary installations are usually powered from a three–phase power grid or can have universal power - from any standard voltage. Mobile installations can also be connected to the local power grid or equipped with an autonomous diesel generator.
The control of modern fog-forming equipment is carried out remotely via a computer or from a remote control, depending on specific conditions. The control system may include a pressure sensor at the outlet of the nozzle and a water flow meter, an hour meter, a safety system that turns off the installation in the absence of water.
Since the fog-forming equipment is constantly in contact with moisture, all its metal parts must be made of corrosion-resistant materials and have a high-quality powder coating
The main elements of high-pressure misting systems:
· high pressure pump,
· filters for water,
· high-pressure main and auxiliary pipelines,
· clamping,quick-release, threaded and reduction fittings
· spraying nozzles,
· system control unit,
· fasteners, etc. accessories according to the project
Experts believe that the use of fog systems in rooms in some cases is much more profitable than the use of ventilation: fog systems consume about 5% of the energy of a conventional ventilation system, and the cost of installing a fog system is only 40% of the cost of installing a conventional ventilation system.
The use of a mist humidification system leads to an increase in productivity and an increase in economic indicators of production.