Chad's Combo 01
complete range of filter cartridges and bags are engineered for greater performance in Donaldson® Torit® cartridge and baghouse dust collectors, or can be used to enhance performance in other manufacturer’s collectors.
Only Donaldson offers Ultra-Web® nanofiber media technology in its cartridge filters for high initial efficiency, excellent dust cake release during pulse-cleaning, and better efficiency throughout the filter life, even on submicron particles.
We also provide a complete line of filter bags in a wide variety of fabrics to fit your application needs, including PTFE membrane laminated to the surface, or other specialty bag options. Our proprietary Dura-Life™ twice the life filter bags provide lower maintenance costs, 99.9% efficiency and increased energy savings over standard polyester bags.
collector was the industry’s first cartridge collector engineered specifically for mist collection. Designed to collect oil, water-soluble and synthetic coolant mists from a variety of machining operations and other industrial processes, Dryflo offers unparalleled filtration efficiency and performance in a comprehensive range of models designed to fit various application needs. In tests conducted by the University of North Carolina (UNC), Dryflo was shown to be the only mist cartridge collector to offer increased efficiency over time, resulting in longer filter life and reduced filter replacement costs.
It can be used individually or in combination to meet the exact needs of your wet machining operation. The Dryflo design has several configurations such as machine-mountable, central system and packaged system that can meet your plant layout requirements.
The award-winning Downflo® Oval 1™ (DFO) family of dust collectors—the only cartridge collectors with oval-shaped filters—provides higher filtration capacity in a smaller footprint. The advantage is DFO’s unparalleled design and high performance components. Engineered with unique oval-shaped cartridges, exclusive Ultra-Web® filter media and enhanced pulse-cleaning technology, DFO provides up to 25 percent more airflow than same-sized cartridge collectors, allowing manufacturers to increase collection capacity without adding a larger collector or maintain collection capacity with a smaller collector.
With this new process, baghouse dust is mixed with water. The "blackwater" mixture then is blasted with intense ultrasonic energy and advanced oxidants are added. This mixture is sent to a clarifier (separation tank) in which the fines are removed from the clay and advanced oxidant water solution. The advanced oxidant blackwater then is sent to the sand cooler and mullers. The clay removal from this dust is effective as the waste fines contain only 4% clay. Neenah only used baghouse material from a collector drawing from the green sand system and slowly increased the addition rate of dust to the system.
Although the exact science involved in the reactivation of the clay and seacoal is still under investigation, the results were clear to Neenah with its R&D Plant 3 system. Compared to its baseline data (from before the sand system optimization program was begun), the foundry realized a 30% reduction in premix usage. The foundry also saw up to a 30% reduction in new sand additions because it doesn’t need to add new sand in comparable levels to new bond. In terms of green compressive strength of the sand, the foundry has seen an increase of up to 6 psi with advanced oxidation. In terms of emissions, the foundry reports a 75% reduction in volatile organic carbons since 1995, and up to a 35% reduction in benzene emissions (depending on cored vs. uncored castings).
These positive results were affirmed by little to no change in green sand system operating conditions such as loss on ignition, methylene blue clay, compressive strength and compactibility, and no increase in casting scrap levels.
This leads to possibly the most important benefit to Neenah since the introduction of advanced oxidation—sand system predictability.
"Our sand system is easier to manage," said Andrews. The foundry isn’t constantly introducing new sand and bond to makeup for lost properties.
"The greatest advantage added by the advanced oxidation system is that it makes the sand system more predictable," said Jeff Goudzwaard, senior environmental engineer. "It allows the foundry to focus on the production process and ensure casting quality."
In February 2000, Neenah added a full-scale advanced oxidation system to its Plant 2 sand system feeding a high-production vertically parted mold line. For this system, Neenah treats the water being added to the sand mullers and coolers and is performing a full-scale reintroduction of baghouse material into the molding system. During the first year of operation, the plant has seen similar reductions in bond additions to this sand system as well as a 50% reduction in VOC emissions and a 33% reduction in benzene emissions. Neenah has made initial plans to add a full-scale advanced oxidation system to Plant 3 to replace the current R&D system.
"When the advanced oxidation is turned on, there is an immediate and dramatic reduction in the smoke from the mold line," said Andrews. "In addition, the molding supervisor sees a measurable reduction in the premix requirement."
Neenah took the next step with the advanced oxidation system (on a prototype level) and began reintroducing baghouse dust material into the sand system. Green sand baghouse dust can contain up to 40% clay. However, previous experience had led Neenah to be cautious in this next step.
"Green sand systems in foundries are critical and must be given due attention and respect," said Andrews. "To haphazardly throw dirt and dust in is a mistake."