Whirl/Wet Dust Collection – Case Study

Whirl / Wet Dust Collection

Case studies by application

Metalworking:

AEROSPACE
Aerospace metalworking shop chooses Tri-Mer for aluminum dust collection.

A high speed machining and grinding center specializing in aerospace projects specified a Whirl Wet for aluminum dust collection.

Whirl Wet has been a leading choice for the collection of particulate and fines from aluminum, magnesium, Monel, and titanium for decades, due to its elimination of explosion hazard. Aluminum material that is 420 microns and finer has high explosion potential, and the design of the Whirl Wet makes this a virtual impossibility.

 

Whirl Wet is a high efficiency industrial dust collector that thoroughly scrubs the dust and traps the particles for capture. Whirl Wet is also self-cleaning, and will not allow fine particulate to agglomerate as sludge on the exhaust vent interior – another important note applicable to aerospace applications. Whirl Wet operates in the 99%+ efficiency range for a wide range of micron sizes. It uses very little water, and requires only minimal quantities of make-up water.

 

This Whirl Wet is all-polypropylene; units are also manufactured in steel, stainless steel and engineered plastics.

This aluminum dust collection system is a Model H, and was supplied with an automatic timed drain down system that allows for automatic removal of collected material.

GRINDING
Whirl Wet provides high efficiency wet dust collection for Delphi Automotive.

 

Tri-Mer dust collection technology is used by Delphi Automotive. Four units were selected as replacements for dry collectors. Each unit serves four grinding (or shot blasting) stations. Capacities range from 425 to 52,500 cubic ft./minute.

 

The units accommodate very heavy loadings under continuous use, and allow regular maintenance without interrupting production. Equally important, the Whirl Wets eliminate concerns about sparks from hot metal fines – a major maintenance dilemma.

In this application, the Whirl Wets are 99%+ efficient in capturing fines ten microns and larger. Operational advantages of the units include quiet operation, very low water use, and a design free of internal moving parts. This latter point was regarded as beneficial because conventional collectors incorporate spray nozzles, pumps, and disposable bags, all of which increase the time and cost of maintenance.

The Whirl Wets manufactured for Delphi Automotive are PLC-controlled for highest reliability, and continuous monitoring of pressure, flow and water levels.

METAL FINES
American Racing Equipment is one of the world’s largest aftermarket wheel manufacturers, offering more than 100 precision-crafted alloy wheel styles.

 

To collect particulate and metal fines from its cutting and grinding operations, American Racing has installed six Model H Whirl Wet dust collectors at its manufacturing facility in Queretaro, Mexico.

The Whirl Wet systems are all-plastic (polypropylene) and operate at 99%+ efficiency. Whirl wet dust collectors are self-cleaning, and do not use “wear” parts such as bags, pumps or nozzles.

They use minimal water, very little energy, and operate virtually maintenance-free.

 

Whirl Wet dust collectors are well suited for metal fabrication and are used for metal cutting, grinding and sawing operations. They are also used for collecting extremely fine metal dusts from the machining of aluminum or platinum.

 

Whirl Wet dust collectors are superior to dry collectors wherever exotic metal dusts are generated, because there is no explosion hazard with Whirl Wet dust collection technology.

METAL WORKING
Metal products manufacurer selects Tri-Mer wet scrubber for metalworking dust.

 

A manufacturer of precision metal components chose a Whirl Wet Scrubber for the collection of particulate from multiple machining operations. The customer debated between an all-polypropylene unit, or a mild steel unit with an epoxy liner, ultimately opting for the polypropylene. (Tri-Mer also manufactures this system in PVC, PVDF and stainless steel.)

 

Polypropylene is a thermoplastic polymer that’s ideally suited to continuous duty equipment such as the Whirl Wet. It is damage-resistant and resilient, and will not delaminate or embrittle over time. The system provides 99%+ efficiency on particles 10.0 microns and larger. It uses very little water.

 

The Whirl Wet Scrubber chosen is a 4200 cfm Model M, a format with a manual clean-out that is often preferred where dust volumes are low. Tri-Mer also offers the system with an automatically timed drain-down system or, for heaviest dust loadings, the Model MCD (Modular Conveyor Dragout) which allows clean-out without pausing production.

POLISHING
True Temper Sports selects Tri-Mer Industrial Dust Collection System.

 

True Temper Sports is the leading producer of golf shafts. Steel shafts are manufactured in True Temper’s plant in Amory, Mississippi, which also manufactures bicycle frame components, and steel products for the automotive and recreation industries.

 

True Temper’s steel golf shafts are the product of 41 individual manufacturing steps. Among the most critical is polishing, a precisely controlled abrasive belt process which prepares the metal for plating baths of duplex nickel, then chrome. These final steps are what give the shafts their perfect, high-gloss shine.

As with all metal polishing operations, the safe and efficient collection of airborne particulate is a key concern. True Temper decided to replace one of several polishing process dust collectors, which, due to internal corrosion and an increasing demand for maintenance, had become obsolete. The company considered several alternatives, including both wet and dry dust collection equipment.

 

True Temper chose a Whirl Wet Model MCD (“modular conveyor drag-out”) wet dust collection system manufactured by Tri-Mer Corp.

Whirl Wet systems serve a broad range of metal grinding and polishing operations, including those involving volatile materials such as titanium and magnesium. Because the system is effective for the collection of all particulates one micron and above, both soluble and insoluble, Whirl Wet dust collection systems are also used throughout the food, chemical, and aggregate industries.

The Whirl Wet unit chosen by True Temper is mild steel, with stationary polypropylene impellers. A corrosion-resistant liner protects mild steel wetted surfaces on the interior of the collector. Because the Whirl Wet impellers are 100% polypropylene and resist the accumulation of the collected material, corrosion in the impellers and blockage within the impellers is prevented.

 

Tri-Mer has systems serving similar applications that have demonstrated a 20-year service life and longer. Whirl Wet units are manufactured in 100% polypropylene, 304 and 316 stainless, FRP and PVC, in addition to mild steel.

 

Systems are supplied with one of three disposal options: manual, timed drain-down or, as was the case with True Temper, Modular Conveyor Dragout (MCD). The latter is recommended for heavy dust load applications, including grinding and polishing operations, because it allows quick, easy removal of residue without shutting down the polishing operation – or even the dust collector itself.

SANDING
Harley Davidson shines with Industrial Dust Collector for sanding and polishing.

 

Gabilan Manufacturing produces all the mufflers used on Harley Davidson motorcycles. Recently, the Salinas, CA company installed a Whirl Wet industrial dust collector – its third – to serve a metal polishing operation.

 

“This operation is critical to chrome plating,” explains Gabilan’s Director of Engineering. “What attracted us to the Whirl Wet industrial dust collector was its polypro construction. Other wet collectors we knew about didn’t hold up very well, no matter what they were coated with. Metal dust fines, plus water, will, sooner or later produce rust in any metal unit. And other non-metal wet collectors we considered were too costly. Whirl Wet had the best design, and was the most competitively priced.”

 

Three Whirl Wet industrial dust collector units are installed in the same facility; all interface with polishing or sanding operations. Collected material is processed through a magnetic filter which separates-out the fines. The system offers significant advantages in terms of housekeeping and clean-up, and is also in line with the company’s ‘safety first’ commitment.

Food/Pharmaceuticals:

BAKERY
Bakery products supplier chooses Tri-Mer Wet Dust Collecting System.

A manufacturer of pies, biscuits, buns, and crusts for many of the world’s largest food chains and retailers selected a 525 cfm Model H Whirl Wet dust collector to collect particulate from sugar and cinnamon dust. Whirl Wet’s efficiency on these dusts is exceptionally high: 99% for particles 10.0 microns and larger, 98% for particles 5.0 microns and larger.

 

This Whirl Wet dust collecting system is manufactured from solid 1″ polypropylene with a NEMA 12 enclosure. Tri-Mer also makes systems for food dusts from PVC and other engineered plastics, and from stainless steel.

 

Tri-Mer is a leading supplier of dust collector technology for food and pharma applications. Its Whirl Wet systems have been used in every type of food manufacturing operation, from ingredient blending to packaging. Systems use minimal water, and have no internal moving parts – a major reason why reliability is exceptionally high and maintenance requirements are very low.

BREADING
Fishery Products International, División de ConAgra, Escoge Tri-Mer.

 

Un Whirl / Wet de 5000 CFM ha sido diseñado para Fishery Products International.

La aplicación es una línea rebozado/apanado donde el exceso de harina es removido antes de la cocción, creando el polvo que de lo contrario se acumularía en las tuberías y otras superficies. En aplicaciones como esta, los sistemas Whirl / Wet contribuyen enormemente al mantenimiento de un ambiente limpio.

 

Un factor clave a favor del Whirl / Wet era el éxito de la tecnología WW en Pierce Food, la división de avicultura de ConAgra, que también usa productos higroscópicos para rebozado. La altísima humedad de ambos ambientes rápidamente taponaría los filtros de mangas, convirtiéndolos en inútiles. Por el contraste, el Whirl / Wet es el único sistema adecuado a estas aplicaciones de alimento industriales.

 

Fishery Products International se especializan en la recolección y el procesamiento primario de pescados y mariscos, y el procesamiento secundario de alimento marino de valor añadido. Es la compañía de mariscos más grande de Canadá.

FOOD DUST
Systems integrator specifies Tri-Mer Whirl Wet Dust Collection System.

 

A specialist in ingredient handling and mixing systems for the food, beverage and pharmaceutical industries specified a Whirl Wet dust collection system for food dusts.

The unit is a Whirl Wet, manufactured in all-polypropylene, with Allen Bradley controls. (In addition to polypropylene and other engineered plastics, Tri-Mer manufactures the Whirl Wet in stainless steel for these applications.)

 

Whirl Wet has long been the dust collection system of choice for food and beverage companies for 3 reasons. It has a high collection efficiency: 99%+ for particles 10 microns and larger; 98% for particles 5 microns and larger. It is self-cleaning. And its unique design has no internal moving parts to wear or replace.

 

The system chosen, a Model H, streamlines the management of collected particulate using an automatically timed drain-down system. Other models offer manual disposal, or, for heaviest dust loadings, an MCD model allows particulate removal without system pause. The system specified for this application has a 3570 cfm maximum capacity.

SPICE MANUFACTURING
Whirl Wet Dust Collector System chosen for processing and packaging operations.

 

A leading manufacturer of spices has repeatedly chosen Tri-Mer dust collector technology for use in its processing, weighing and packaging operations. Whirl Wet captures 99% of particles 10.0 micron and larger, and has been widely used in food processing for decades.

 

The dust collector specified is a 1000 cfm (1050 maximum cfm) Model H, engineered for continuous duty. It has an automatically timed drain-down system for removal of collected material from the hopper. It is one of 3 disposal options offered on the Whirl Wet.

The system is all-polypropylene; Tri-Mer also manufactures its dust collector systems in stainless steel for food and pharma applications. Control is via an Allen Bradley PLC.

 

The Tri-Mer dust collector design uses very little water; the only make-up water required is what’s needed to compensate for evaporation. Whirl Wets can be supplied alone, or as a package, with material handling.

PHARMACEUTICAL
Whirl Wet Dust Collectors preferred for pill coating operation.

 

A major multi-national manufacturer of pharmaceuticals and vaccines chose Whirl Wet technology for a pill coating operation. The aqueous sugar solution created heavy loadings of sticky overspray in the 3 micron range. This blinded the existing baghouses after just six batches despite the use of PTFE cartridges – (the best available option for baghouses used in this type of application.)

 

Six 2500 cfm Whirl Wet units were installed. The units are carbon steel, with manual drag-out. Whirl Wet dust collectors are exceptionally well-suited to the collection of dusts three microns and above. Energy generated inside the unit will not allow the system to clog under any operating conditions, and agglomeration and sticky residues never become an issue.

 

Whirl Wet dust collectors have no internal moving parts; they are also self-cleaning and highly energy-efficient. Water use is low: following the initial charge at the time of installation, only minor water additions are needed to compensate for evaporation and drag-out.

 

The dust collectors are 99%+ efficient in this overspray collection application. Whirl Wet technology is widely used throughout pharma, for the collection of dusts from crushing, mixing, pelletizing, tabletting and packaging operations. Systems are manufactured in stainless steel and engineered plastics, as well as carbon steel.

 

For the collection of submicron particulate in pharmaceutical processing, Tri-Mer offers the CCS Cloud Chamber Scrubber.

COSMETICS
Whirl Wet provides High Efficiency Wet Dust Collection for Erickson Cosmetics.

 

Production was accelerating at Erickson Cosmetics, a Chicago-based maker of talc and cornstarch-based products for the Mennen Division of Colgate-Palmolive and other companies. The 320,000 sq. ft. plant is highly automated and, while the primary powder line operated within regulatory guidelines for dust control, Todd Nelmark believed there were strong reasons to consider automatic dust collection.

After evaluating several wet dust collection alternatives, Nelmark chose a Whirl / Wet unit made by Tri-Mer Corporation.

 

The primary challenge was to collect airborne dust while not “pulling” powder material from the fillers. Velocity had to be tightly controlled.

The unit that best served Erickson’s requirements was an 1800 cfm Whirl / Wet. The unit operates only while powders are being filled. Dust is collected from 30 point sources and funneled to the unit. A 10 hp medium pressure fan creates the needed vacuum.

The air is passed under high velocity through a fixed position, dual-opposed blade system. The aggressive mixing of the dust-laden airstream is injected through a linear slot in the lower blade assembly.

Rotation is accelerated, droplets in the airstream are eliminated through a mist eliminator, and particulate is deposited on the bottom of the unit for recovery.

The system proved to be 99%+ effective for the collection of soluble and insoluble particles above one micron.

Aggregate:

AGGREGATE
Dixie Cut Stone & Marble chooses Whirl Wet High Efficiency Wet Dust Collector.

Dixie Cut Stone & Marble finishes Indiana limestone for the dimensional stone industry. Dixie management wanted “best available” dust collector technology to maximize both efficiency and housekeeping benefits.

 

Tri-Mer supplied two Whirl / Wet units with top-mounted blowers. Collected material is discharged manually after settling. The system operates with minimal water consumption and consumes very little energy.

 

Tri-Mer is a leading supplier of air pollution control systems to the stone, brick and tile industry. Other applications that may be of interest are Florida Tile, where Tri-Mer supplied a Whirl / Wet unit for collecting overspray from a glazing operation, and Hanson Brick.

BRICK CRUSHING
Colector de Polvo para Chancado de Ladrillos y fabricación de Ladrillos Caravista

Hanson Bricks el fabricante de ladrillos más grande de Norteamérica, con una capacidad de más que 1,600 millón de ladrillos. También es el único fabricante de ladrillos Caravista, calcinados en hornos, en su región.

 

Los materiales usados en Hanson son la pizarra y la arena, en una mezcla de 80/20. Para colectar polvos producto de la homogenización de colorantes a base de polvo de arcilla, así como para colectar polvos de maquinas de extender y secadores, la compañía compró un Whirl / Wet fabricado por Tri-Mer Corp.

 

El colector de polvo es un Whirl / Wet del modelo MCD (del inglés Multi Conveyor Drag-out) de 7,000 CFM. El “MCD” es un método para manejar material depositado en el colector de polvo que es patentado a Tri-Mer y que consiste en un tipo de faja transportadora que drena la tolva del sistema y lleva el material a otro punto de la planta. Esto permite la operación ininterrumpida del colector de polvo, aún durante el mantenimiento del mismo.

 

La fabricación y chancado de ladrillos son ambos aplicaciones para el Whirl / Wet.

Los Whirl / Wet son extensamente usados por fabricantes de azulejo/baldosas, piedra y ladrillo, para la colección de partículas y polvos, y para la colección del exceso de rocío en trabajo de vidriado.

 

Un Whirl / Wet de 5000 CFM ha sido diseñado para Fishery Products International.

La aplicación es una línea rebozado/apanado donde el exceso de harina es removido antes de la cocción, creando el polvo que de lo contrario se acumularía en las tuberías y otras superficies. En aplicaciones como esta, los sistemas Whirl / Wet contribuyen enormemente al mantenimiento de un ambiente limpio.

 

Un factor clave a favor del Whirl / Wet era el éxito de la tecnología WW en Pierce Food, la división de avicultura de ConAgra, que también usa productos higroscópicos para rebozado. La altísima humedad de ambos ambientes rápidamente taponaría los filtros de mangas, convirtiéndolos en inútiles. Por el contraste, el Whirl / Wet es el único sistema adecuado a estas aplicaciones de alimento industriales.

 

Fishery Products International se especializan en la recolección y el procesamiento primario de pescados y mariscos, y el procesamiento secundario de alimento marino de valor añadido. Es la compañía de mariscos más grande de Canadá.

NATURAL STONE
Natural stone manufacturer selects Tri-Mer Wet Dust Collector.

 

A manufacturer of natural stone and composite products for countertops, landscaping and commercial applications, chose Whirl Wet industrial dust collection technology. The system is a Model H, which is manufactured in capacities from 425 cfm to 50,000 cfm and higher. The system selected has a maximum 5250 cfm capacity; an automatically timed drain-down system provides efficient management of particulate.

 

Whirl Wet performs at 99% efficiency and higher for particulate 10.0 microns and large, making it ideal for marble, limestone and sandstone dusts. Water use is low, and the only water additions are those needed to compensate for evaporation.

 

Whirl Wet is self-cleaning, and energy generated inside the unit will not allow the system to clog under any operating conditions. The plugging (“blinding”) that plagues some dust collector designs is not an issue with the Whirl Wet.

This unit is all polypropylene, a material compatible with abrasive materials. Tri-Mer also manufactures its wet dust collector in mild and stainless steels, PVC and PVDF.

TILE GLAZING
Florida Tile upgrades from Baghouse to Wet Collection System.

 

Florida Tile experienced high maintenance, and unplanned shut-downs due to a dry scrubber (bag house) on a glazing operation. The high weight and moisture of the glaze made it difficult to contain the overspray and caused frequent production stoppages. Maintenance was costly, involving both the bag house and ventilation hoods.

 

Florida Tile changed from dry dust collection to wet dust collection, and first installed two polypropylene Whirl Wet dust collectors. Three additional Whirl Wet dust collectors were installed subsequently to replace the remaining bag houses.

 

Whirl Wet dust collectors are self-cleaning and will not clog, or stop production. Captured material is reclaimed from scrubbers and hoods at close to 100% efficiency. The system is virtually a closed loop: incoming water is used, then recycled, leaving as sanitary sewage or steam. Water use and energy use, are both low.

 

Whirl Wet dust collectors are widely used by manufacturers of tile, stone and brick, for the collection of particulate and dusts, and for the collection of overspray in glazing operations.

Battery Manufacturing:

LEAD ACID CANADA
Surrette Battery Company replaces baghouse with Whirl Wet Dust Collector.

Surrette Battery Company Limited, Springhill, Nova Scotia is a leading lead-acid battery manufacturer, and Canada’s only independent battery manufacturer. The battery company manufactures long-life, true “deep cycle” battery systems for railroad, marine, industrial and renewable energy applications.

 

Surrette Battery wanted a corrosion-free system that would withstand acid fumes from a paste mixer when materials were damp, and collect the dusts that were generated when materials (which had high concentrations of lead oxide) were dry.

 

A baghouse met environmental requirements, but the company’s proactive management wanted a more reliable dust collector that had minimal maintenance requirements and would accommodate future growth. The answer was an all-polypropylene Whirl Wet dust collector.

 

Whirl Wet dust collector systems are widely used throughout the battery industry for collecting lead oxide dusts in battery paste-making operations. These wet dust collector systems operate quietly, accommodate heavy dust loadings and are self-cleaning. Whirl Wet dust collectors can provide for continuous, “24/7” operation.

The 2500 cfm Whirl Wet dust collector chosen by Surrette Battery collects dusts 1 micron and above at 99.5% efficiency. These dust collector systems will not clog or blind in high-humidity conditions, and are unaffected by acid fumes. Water use is low, and water level is maintained automatically.

For abatement of sulfuric acid fume, see our fume scrubbers

LEAD ACID ECUDAR

Volatile Dust:

ALUMINUM DUST
A facility equipment contractor specified Tri-Mer’s aluminum dust collectors for a new manufacturing plant. The systems specified were Model Ms, with the manual particulate disposal option.

Tri-Mer manufactures the Whirl Wet in capacities ranging from 425 cfm to 52,500 cfm; the wet scrubbers selected for this application are each 4200 cfm.

 

The systems are solid 1″ polypropylene, a robust thermoplastic with a long track record of continuous service in challenging environments. The Whirl Wet is also manufactured in other engineered plastics, as well as mild steel and stainless steel.

 

Tri-Mer Whirl Wets are 99%+ efficient over a wide range of micron sizes. They are self-cleaning, and have no internal moving parts to wear or replace; a fixed-position, dual opposed blade system generates the energy needed to intensely mix the particulate and water. Systems use very little water and only require water make-up to compensate for evaporation.

EXOTIC METALS
A Tri-Mer Whirl-X® was engineered for the safe, efficient collection of metal fines from grinding, sanding and deburring operations involving aluminum, magnesium, titanium, beryllium, uranium and other exotic metals.

The system is a cost-effective, high-performance alternative for these and similar applications that create an explosion hazard for dry and bag collectors.

 

The Whirl-X industrial dust collector is manufactured in mild steel, stainless steel, and special alloys such as Hastelloy. It is also offered in all-polypropylene, a feature which prevents the accumulation of collected dusts, eliminates corrosion and minimizes maintenance.

 

Whirl-X captures 99.9% of all dusts five microns and larger. It can be ducted to multiple stations or sources, and is low noise.

Its advanced design does not use pumps, nozzles or bags – three costly and consumable components which are common to conventional collectors. It is self-cleaning, and, the patented whirl chamber has no internal moving parts.

 

Whirl-X uses very little water, an important factor in areas where utility rates are high. Following initial charge, the only water required is a small amount to compensate for evaporation and dragout. Systems can also be engineered to return air to the plant in some instances, reducing HVAC costs.

Whirl-X Systems are manufactured in capacities from 425 cfm to 50,000 cfm. Depending on size, reclamation requirements and other factors, three disposal alternatives are offered. Manual or timed-drain systems are offered for modest dust volumes; for highest volumes and lowest maintenance, an automatic conveyor dragout, “zero-shutdown” format is offered.

Tri-Mer manufactures a broad range of industrial dust collectors for metalworking and other process environments.

TITANIUM DUST
Whirl Wet collection system chosen to capture titanium and other metal dust.

A diversified Fortune Top 10 company, and long-time user of Tri-Mer gas and particulate control technology for its facilities worldwide, chose a 4200 cfm Whirl Wet Dust Metal Collection System to capture titanium dust emissions from machining operations. Whirl Wet captures 97% of particles 3.0 microns and larger and 98% of particles 5.0 microns and larger, making it ideal for metalworking operations of all types.

 

The Whirl Wet dust collection system inherently controls dust combustibility. By contrast, dry collectors are at risk for dust explosions and require explosion protection add-ons to meet NFPA standards. (For applications involving titanium and similar dusts, dry collectors are not even an option, because none meet NFPA standards.)

This 4200 cfm wet dust collection system is manufactured in stainless steel with a PVC mist eliminator. (Tri-Mer also manufactures the Whirl Wet in mild steel and thermoplastics, including polypropylene, PVC and PVDF.)

 

To accommodate heavy dust loadings, the company specified a Model MCD, (Modular Conveyor Drag-out), which deposits particulate as a filter cake in the bottom of the unit for easy disposal. Its unique drag-out feature allows uninterrupted operation, even during material removal.

The Tri-Mer Model MCD has a long history of reliable low-maintenance operation and uses very little water: the only make-up water required is what’s necessary to compensate for evaporation. The MCD is often selected by companies who want to simplify disposal, or recover/recycle collected material.

FERTILIZER MANUFACTURING
Efficient dust collection, plus product recovery benefit fertilizer manufacturer.

Mears Fertilizer manufactures fertilizers and packages a recovered by-product, brine, for use as “ice melt.”

 

Collecting dry fertilizer dusts from manufacturing and packaging operations is a major operations priority. Mears had used various types of dry “bag house” equipment, but results had been unsatisfactory.

 

For a new installation, the company was determined to avoid bag houses. The area where the new equipment would be installed had high humidity levels, so dry collectors were ruled out because they plug “blind” in moderate-to-high-moisture environments.

Other factors included high dust loading, dust composition that was very fine (4-5 microns) and highly hygroscopic, and the recovery of collected material.

 

Modeling showed that a Whirl Wet dust collection system was the best alternative. Whirl Wet has a long track record for collecting soluble and insoluble dusts at efficiencies between 99% and 99.8%. It does not have external pumps or recirculation devices, or internal moving components. Nothing moves inside the unit, except air.

Whirl Wet employs a unique process to create intense mixing of the dust particles and water. To infuse dust particles with water droplets, the mixture is passed under high velocity through a fixed-position, dual-opposed blade configuration. To increase turbulence, a tangential airstream is injected into the lower blade assembly. Rotation is accelerated, droplets in the airstream are isolated by an integral mist eliminator positioned downstream, and particulate is deposited on the bottom of the unit for recovery (or disposal). Water levels are maintained automatically.

 

The Whirl Wet is self-cleaning. And because the unit is manufactured of solid polypropylene, no lining, coating or reinforcement is ever needed. The unit is housed in a semi-heated room, and water is not heated. There is no ramp-up required; the system is at full operating potential at the moment of start-up.

Whirl Wet units are manufactured in mild and stainless steels, PVC, FRP and polypropylene. The free sulfuric acids involved in fertilizer formulas made solid polypropylene the best construction choice for the Whirl Wet due to polypropylene’s resistance to corrosives.

 

The Whirl Wet system collects the “face powder-fine” dusts from Mears’ processing lines at efficiencies averaging of 99.5% and higher. Beyond the benefits of clean indoor air and highly efficient material recovery, the company benefits from simpler, less costly housekeeping.

Chem Petrochem:

CHEMICAL POWDER
Industrial Dust Collector Systems capture chemical powders.

A multinational chemical manufacturer specified Tri-Mer Industrial dust collector technology for a mixing and blending operation. The system provides 99%+ collection efficiency over a wide range of micron sizes.

 

Whirl Wet industrial dust collection is a leading choice in chemical and pharmaceutical environments, where operation is often continuous and preference is given to equipment with a strong track record of reliability and low maintenance. Whirl Wet is also preferred where dusts are volatile or explosive.

 

This Whirl Wet system has a capacity of 6300 cfm, and is manufactured in 316 stainless steel. Tri-Mer also manufactures dust collector systems in mild steel, PVC, PP, and PVDF.

This Whirl Wet is a Model H, with an automatically timed drain-down system for easy retrieval of collected particulate. Tri-Mer also offers a manual clean-out format, and, on the other end of the spectrum, the Model MCD (Modular Conveyor Dragout) which allows particulate removal without system shut-down and is widely specified for applications with heavy loadings.

FIRE PREVENTION
Whirl Wet Dust Collection System proves ideal for polishing operations.

Gabilan Manufacturing, Inc. (Salinas, CA) produces all the mufflers used on Harley Davidson motorcycles. Quality is paramount: the polishing is preparation for chrome plating – arguably the most critical finishing process for high-end bikes.

 

When new grinding and sanding equipment was installed, Gabilan considered several options for dust collection, finally choosing a cartridge system with spark arrestors.

Within a few weeks of installation, however, concerns mounted, as superfine metal dusts caused a series of small fires within the dust collector interior. A CO2 deluge system was added to increase the margin for safety.

 

Realizing the ongoing potential for problems, however, the company investigated other solutions. In addition to safety, life cycle costs, the feasibility of installing the unit out-of-doors, remote from the manufacturing area, and construction material options were considered.

 

A decision was made to install a Whirl Wet. Key to the decision was its non-corrosive, all-polypropylene construction, and competitive price. In addition, the Whirl Wet does not have external pumps or recirculation systems, so installation out-of-doors was possible.

 

Water consumption, a major concern in California, is very low for the Tri-Mer system. In contrast to wet systems that rely on dynamic precipitation or flowing water films, the only water needed by the Whirl Wet after the original charge is that which is required to compensate for evaporation or drag-out. On average, the Whirl Wet uses 70-80% less water than other wet systems of equal capacity.

PETROCHEMICALS
Petrochemicals manufacturer chooses Tri-Mer Industrial Dust Collection System.

A large multinational manufacturer of chemicals, polymers and other petrochemical derivatives chose a Whirl Wet industrial dust collection system to collect particulate from a pellet dryer. The system, a Model H, has a capacity maximum of 5250 cfm.

 

Whirl Wet uses a unique process to intensely combine water and particulate. The mixture is passed under high velocity through a blade system, where turbulence is increased and rotation is accelerated. Particulate is deposited at the bottom of the unit for recovery or disposal. This Model H has an automatically timed drain-down system to simplify the removal of collected particulate.

 

Whirl Wet industrial dust collection systems are engineered for low water use, which has made them popular throughout the American west, as well as the Middle East and other regions where water is costly.

This Model H is stainless steel, with a NEMA 12 controls enclosure. Tri-Mer also manufactures the Whirl Wet in mild steel and various engineered plastics.

PUGMILL
Tri-Mer Industrial Dust Collection chosen by Florida county.

A Whirl Wet 4200 cfm Whirl Wet industrial dust collection system was chosen to capture particulate from a pug mill used by the Public Works Department to make road base. The Whirl Wet is ideally suited to this application: it efficiently captures 99% of particulate 10.0 microns in size and 98% of particles 5.0 microns in size, while using very little water.

 

The system specified is a 4200 cfm Model H. It was manufactured from solid polypropylene, a strong, resilient material that is flexible and fatigue-resistant. It features a timed drain-down system for simplest removal of collected material, one of 3 disposal alternatives offered for the Whirl Wet.

 

The Whirl Wet industrial dust collection system has a long, successful track record, with more than 5700 units in use worldwide, in applications ranging from mining to metalworking, food processing to leather tanning.

TANNING
Horween Leather chooses Whirl Wet Dust Collector for high efficiency and safety.

For leather fines and other lightweight, porous materials, dry collection has been thought to be preferable to wet because of the material’s buoyancy.

 

Horween Leather Company challenged that assumption. Originally, two baghouse systems collected particulate, but problems arose with each baghouse. First, cold winter dryness caused high levels of static electricity. Resultant sparks in the ducts headed to the baghouse, creating fire risk.

 

Worse was a problem peculiar to tanning: steel shot embedded in the hides remained through the tanning process and the use of sandpaper on the hides created another fire hazard. The danger was heightened by tanning chemicals.

 

Horween installed a 14,000 cfm Whirl / Wet Dust Collection System, ducting three machines to the unit. The Whirl Wet eliminated the risk of fire and explosion at the finishing stations. With dust collection efficiency of 98.6%, dust throughout the plant was eliminated and product quality improved.

WASTE MANAGEMENT
Whirl Wet Dust Collector System chosen by waste management firm.

A company specializing in waste management services, recycling, and de-packaging solutions specified a Model H Whirl Wet Dust Collector System to capture dusts from solid waste processing. Whirl Wet captures 99.0% of particles 10.0 micron in size and 98% of particles 5.0 micron and larger, so it is ideally suited to this application.

This 7350 cfm wet dust collection system is manufactured in all-polypropylene*, a popular choice for this equipment. Polypropylene is a high-strength, monolithic material that won’t corrode, embrittle, or de-laminate. It has very low moisture absorption, and is exceptionally stress and crack-resistant, so it is ideal for environments where accidental impact can occur from material handling devices.

The Model H chosen for this application is one of 3 disposal options offered for the Whirl Wet. The Model H has an automatically timed drain-down system. Other options include the Model M, which has manual clean-out and the MCD (Modular Conveyor Dragout) which is ideal for high dust loading applications, and which has the advantage of continuous operation even during maintenance.

Like all Whirl Wet systems, the Model H has a long history of reliable low-maintenance operation and uses very little water: the only make-up water required is what’s necessary to compensate for evaporation.

* Tri-Mer also manufactures the Whirl Wet in mild steel and thermoplastics, including polypropylene, PVC and PVDF.

 

WAX PRODUCT
Wax products producer achieves 99% efficiency using Tri-Mer Dust Collection Equipment.

The company’s first priority was a system that would collect fugitive particulate with consistently high efficiency. Low utility cost and minimal maintenance were also important. Wet particulate collection was specified at the outset because the vapor carried with the airstream would quickly blind baghouse, cyclonic and other dry systems.

 

Whirl Wet dust collection equipment; 5000 and 7500 cfm, respectively, were used. In one area, materials are dispensed as dry particles in powdered form into lidded kettles. As these materials are added, the Whirl Wet pulls outside air through the lid, preventing release of particulate. Other materials are generally added as solids or as liquids. Components are mixed into molten materials.

Vapors from the jacketed, insulated mixing kettles, approximately 200°F, duct to the larger Whirl Wet unit. Particle size distribution of the incoming airstream is primarily between 5 and 10 microns. Particulate loading is heavy, because sticky vapors are entrained in the airstream.

 

Notably, the Whirl Wet has no internal moving parts and is self-cleaning, so the sticky character of the material does not present maintenance issues for the collector, or the ductwork.

The Whirl Wet also facilitates a process where moisture must be removed under negative pressure, (standard design is 20″ of negative pressure) its fan pulls out the moisture-laden air, saving process time and steps. The Whirl Wet removes a substantial amount of particles from the airstream.

 

To control process odors and VOCs, a 3000 lb. active carbon bed filter was placed after the 5000 cfm Whirl Wets units. Sandwiched between them is a bank of DOP-type “furnace filters” that first remove the smaller (1-3 micron) particulate.

 

This assures that the costly fluidized bed carbon filter doesn’t blind. Blinding would occur as a result of vapors suspended in the warm exhaust stream. The filters allow the air to cool and the particles to solidify on the media. Without the filter bank, the carbon filters have a service life of 4-5 days. With it, it’s 3 months.

To compensate for the higher pressures and fan velocity, silencers were provided on both Whirl Wet units to attenuate noise to a level of 70-75 dB for the larger unit and 80-81 dB for the smaller unit.

The two Whirl Wets are constructed with mild steel material with a proven service life of 20+ years.

Droplets eventually accumulate on the de-misters, but their PVD construction makes removal an easy task. Energy generated inside the unit will not allow the system to clog under any operating conditions, including high particulate loading.

 

Utility costs are minimized due to a low power draw – despite the greater fan requirements – and the fact that water use is low. Water level is maintained automatically, and make-up water is only necessary to compensate for evaporation or sludge removal.

 

Whirl Wet operates in the 99%+ efficiency range for a wide variety of applications and over a wide range of micron sizes for both soluble and insoluble particulate. It is widely used throughout the CPI, and within the food, pharmaceutical and aggregate sectors.

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