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Ballpoint Tips Making Mist Collector : Complete Selection Guide!

Ballpoint Tips Making Mist Collectors
Ballpoint Tips Making Mist Collectors

Ballpoint Tips Making Mist Collector : Complete Selection Guide!

Ballpoint Tips Making Mist Collector captures harmful fumes from the source and delivers clean air to the work environment. It contains harmful fumes that may include particles like PM 2.5 , PM 10 , CO2, etc. In this blog post , we will discuss ballpoint tips making mist collectors: a complete selection guide , i .e., parameters that are important when selecting one .

How Ballpoint Tips Making Mist Collector Works?

Fine oil mist, vapor , and smoke are produced during high-speed precision manufacturing of ballpoint pen tips. The oil mist is collected with an Electrostatic Oil Mist Collector.

Key Features & Specs

  • Function: It collects sub-micron oil particles and smoke from sliding head machines or automatic lathes used to shape the metal pen tips.
  • Filtration Technology: It employs electrostatic precipitator (ESP) technology to electrically charge mist particles via a high-voltage ionizer and then collect them on grounded collector plates.
  • Efficiency: Typically 95% – 99% efficient down to 0.5-micron particle size.
  • Filter Reusability: Washable and reusable electrostatic collector cells, with no replacement filter costs and lower operating costs.
Ballpoint Tip Mist Collector Guide!

Ballpoint Tips Making Mist Collector: Selection Parameters

There are different parameters that are important when selecting a ballpoint tips making mist collector ; these are as follows:

Essential Choice Criteria

  • Coolant and Fluid Type: Determine if the micro-machining operation employs neat cutting oil, synthetic emulsions, or water-based coolants. Clean oils produce fine submicron smoke and mist that require high-efficiency media or electrostatic separation, while water-based coolants are typically compatible with centrifugal mist collectors.
  • Airflow Rate (CFM): Determine your cubic feet per minute (CFM) by using the machine enclosure volume (usually enclosure volume × 4 for small precision enclosures) to preserve negative pressure while preventing contamination from escaping through gaps or bar feeders.
  • Droplet and Particle Dimensions: Micro-drilling and turning with a ballpoint tip produce extremely small mist particles and smoke. Ensure the system incorporates a multi-phase method: an initial coarse pre-filter for larger droplets, a depth-loading/coalescing filter for the bulk mass, and a HEPA final stage for particles smaller than one micron.
  • Installation and Base Area: Choose between compact units mounted on machines (to conserve vertical space above sliding-head lathes) or a centralized extraction system if several tip-machining stations operate simultaneously.
  • Fluid Recovery and Drainage: Because precision machining oils are expensive, select a collector that effectively coalesces and drains the recovered fluid back into the machine or a recycling container.

How Filter ON Helps Here:

Filter ON India is a 43-year experienced player in the field of industrial air pollution control systems. With over 70 products available for applications , Filter ON has built strong expertise in this sector. This expertise makes it easier for you to choose the mist collector for ballpoint tips making machines. Filter ON’s knowledge is not limited to selecting the equipment ; we also handle the implementation of the proposed solution at an affordable cost. Our innovative approach, supported by our staff and service personnel, ensures reliable and effective results.

Ballpoint Tips Making Machines Mist: Health Issues

Exposure to mists of oil and coolant during manufacturing processes, such as ballpoint tip machining, can lead to serious respiratory, skin, and systemic health problems if a mist collector is absent or malfunctions.

Main Health Concerns

    • Respiratory Issues: Breathing in droplets (smaller than 20 microns) enables particles to evade natural defenses and reach the alveoli in the lungs. This results in work – related bronchitis, asthma, hypersensitivity pneumonitis, and “machinist’s lung.”
    • Skin Issues: Direct exposure to metalworking fluids leads to irritant and contact dermatitis, folliculitis, and painful “oil acne.”
    • Mucosal Irritation: Airborne mist causes irritation in the eyes, nose, and throat, as well as headaches and nausea from brief exposure.
    • Microbial and Chemical Hazards: Heated coolant liquids promote the growth of bacteria (including Pseudomonas and Mycobacterium immunogenum). Additives such as biocides and agents that release formaldehyde increase sensitization and overall toxicity.
    • Prolonged Carcinogenic Hazards: Heated straight mineral oils produce polycyclic hydrocarbons (PAHs) associated with cancers of the skin, lungs, and stomach, while specific water – soluble additives create nitrosamines.

If your Ballpoint Tips Making machines operate without proper oil mist control, efficiency is being lost daily.

Evaluate your setup or consult an expert like Filter ON India  to select the right system as per requirement, budget and scope. Contact us to learn more….

Frequently Asked Questions:

1. What are the different parameters for selection of Ballpoint tips making mist collectors?

Ans: The different parameters for selection of a Ballpoint tips  mist  collector are Coolant type, Air flow rate,   Particle dimension, Installation and base area, Fluid drainage and recovery.

Ans:A ballpoint tips making machine produces a small amount of high-density oil mist. To effectively filter this fine mist, an Electrostatic Precipitator (ESP) is utilized, which employs electrically charged mist particles via a high-voltage ionizer and then collects them on grounded collector plates and using filters to provide clean air in the work environment. Check here for technology selection, here.

Ans: The major health issues are respiratory issues, skin issues, mucosal irritation, microbial and chemical hazards, and prolonged carcinogenic hazards such as cancer of the skin, lungs, stomach.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune, or mail us at : marketing@filter-on.com

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Pilger Mills Mist Collector : Complete Selection Guide!

Pilger Mills Mist Collector : Complete Selection Guide!
Pilger Mills Mist Collector : Complete Selection Guide!

Pilger Mills Mist Collector : Complete Selection Guide!

The Pilger Mills mist collector is essential for controlling oil mist generated during pilger mill operations. This mist contributes to a polluted work environment, exposing workers to serious health risks, including respiratory issues and irritation. Over time, prolonged exposure may lead to severe health conditions, such as cancer-related diseases.

Selection Parameters: Pilger Mills Mist Collector:

For a Pilger Mill Mist Collector, the main selection parameters are

  • Oil/coolant type – Oil/coolant type is more important in pillar mills because the rolling and lubricating oil characteristics are major factors to decide.
  • Oil flow rate—Higher spray volumes can generate more mist, so oil flow rate is also a deciding parameter here.
  • Mist generation level – It is based on rolling speed, lubrication method, and spray arrangement, so it is also an important factor in deciding mist collectors.
  • Required airflow (m³/hr)—It is based on mill enclosure/working area and extraction points, as this is required to decide CMH for mist collector for pilger mills.
  • Particle size – It determines the required filtration technology and efficiency, but here we recommend ESP (Electrostatic Precipitation) technology for better filtration and achieving the best efficiency.
  • The extraction-point layout is essential for identifying the locations of the roll stand, lubrication zone, and other areas that generate mist. Understanding the exact points of mist generation is crucial for effective mist collection.
  • Duct size & length – The bends and distance affect pressure loss to cover air flow pressure, so duct size and length are also deciding parameters for mist collectors.
  • Filtration technology options include ESP (Electrostatic Precipitation), centrifugal, or multi-stage filtration, depending on the characteristics of the oil and mist. In this context, we recommend ESP because of its high efficiency and long-term suitability.
  • Machine size & layout – It’s another determining factor. Important for mounting and routing.
  • Oil drainage and recovery- They are beneficial in applications where significant oil is collected. ESP-based mist collectors, such as the Filter ON Pilger Mills Mist Collector, offer a distinct advantage for effective oil recovery.
Pilger Mills Mist Collector Guide

Health Risks In Pilger Mills:

Workers can be exposed to oil mist through skin contact, inhalation, or ingestion. According to many health experts, most occupational exposure occurs through skin contact. Oil mist is harmful, but it is often contaminated with other chemicals that make it even more toxic to workers.

Long-term exposure to oil mist has been associated in studies with a higher risk for some cancers. Other health problems linked to exposure include:

  • Contact Dermatitis / Photosensitive Allergy Dermatitis
  • Bronchial asthma
  • Lipoid pneumonitis

The symptoms of high oil mist concentration are

  • Breathlessness
  • Eye irritation Skin irritation
  • Nausea and vomiting
  • Heat
  • Fast Heartbeat
  • Burning sensation in the mouth, throat, and stomach
  • Runny Nose
  • Bronchitis
  • Pulmonary fibrosis
  • Lung neoplasm
  • Benign and malignant neoplasms of the scrotum

How does ESP help in removing mist from Pilger Mills?

A cold-rolling Pilger Mill generates a massive amount of high-density oil mist and heat-generated smoke due to the application of large volumes of lubricants or metalworking fluids that reduce friction and dissipate extreme heat. An Electrostatic Precipitator (ESP) is employed for effective extraction of this fine mist, utilizing electric fields instead of physical mesh barriers. This innovative design enhances efficiency and prevents clogging, a common issue associated with standard fabric or cartridge filters.

Key Benefits of Using an ESP Based Pilger Mill Mist Collector

  • Captures Sub-Micron Fumes: Effective in capturing ultra-fine organic vapors and smoke from pilgering, with particle sizes ranging from 0.01 to 0.1 microns.
  • No Clogging or Filter Saturation: ESP plates are washable and reusable, avoiding issues like pressure drops and high replacement costs common with standard filters.
  • Dual Value (Oil Recovery): Collected oil can be filtered and recycled, contributing to cost savings on raw materials.
  • Constant High Airflow: The absence of physical barriers minimizes pressure drop, leading to significant energy savings in fan operation.

If your Pilger Mills  machines operate without proper oil mist control, efficiency is being lost daily.

Evaluate your setup or consult an expert like Filter ON India  to select the right system as per requirement, budget and scope. Contact us to learn more….

Frequently Asked Questions:

1. What are the different parameters for selection of Pilger mills mist collectors?

Ans: The different parameters for selection of a pilger mills mist  collector are Oil/coolant type, Oil flow rate,  Mist generation level, Particle size, The extraction-point layout, Duct size & length, Filtration technology options, Machine size & layout, Oil drainage and recovery.

Ans: A cold-rolling Pilger Mill produces a massive amount of high-density oil mist and heat-generated smoke from the use of large volumes of lubricants. To effectively extract this fine mist, an Electrostatic Precipitator (ESP) is utilized, which employs electric fields to enhance efficiency and prevent clogging, unlike traditional fabric or cartridge filters. here.

Ans: The major health issues are contact Dermatitis / Photosensitive Allergy Dermatitis, Bronchial asthma,Lipoid pneumonitis.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune, or mail us at : marketing@filter-on.com

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Fume Extraction Standards & Regulations: The Essential Guide to Safer Workspaces and Smarter Investments

Fume Extraction standards and regulations
Fume extraction standards and regulations

Fume Extraction Standards & Regulations: The Essential Guide to Safer Workspaces and Smarter Investments

Global market changes Day by day, manufacturers and companies need to comply with standards and regulations at every manufacturing process, such as welding, brazing, oil mist, dust collection, laser marking, laser cutting, etc. These processes need to comply with the safety standards and government regulations for each process as per the latest government norms specified.

Fume extraction standards and regulations

Safety Standards and Exposure Limits For Workers—Welding Applications:

As per the OSHA factsheet and India's PEL (Permissible Exposure Limits), the welding process is as follows:

OSHA standards for galvanized steel:

OSHA warns of welding hazards in galvanized steel and stainless steel. Galvanized steel, coated with zinc, can cause metal fume fever.

Want to know about health hazards related to welding fumes? Click here to read more.

OSHA standards for stainless steel:

Stainless steel coated with chromium is highly toxic and can cause cancer. Companies have a duty to guarantee that no worker is exposed to levels of chromium greater than 5 µg/m³.

Safety Standards and Exposure Limit for Workers: Oil Mist Applications:

The OSHA Occupational Safety and Health Administration sets permissible exposure limits for air contaminants in metalworking fluids, including oil and solvent mist. These limits are set at 5 milligrams per cubic meter for an 8-hour, time-weighted average (TWA).

The Indian government's Factory Act also follows these standards to control oil and coolant mist exposures in India. Vent lines at lubrication points are also required to collect stray mist.

Want to know about health hazards related to oil mist? Click here to read more.

Safety Standards and Exposure Limit for Workers: Dust Exposure :

As Per OSHA and Indian Factory Act:

Typically, the PEL for total dust is 15 mg/m3, while respirable particles have a lower PEL of 5 mg/m3.

Safety Standards and Exposure Limit for Workers: Laser Marking Applications:

  • The Occupational Safety and Health Administration (OSHA) has established safety limits for laser marking, categorized into different classes based on their power and potential hazards.
  • Class 1 is safe under all conditions, while Class 2 is safe for short viewing times but can cause eye damage if mishandled.
  • Class 3B is unsafe for direct viewing and can cause skin and eye injuries.
  • Class 4 is high-power lasers that can cause skin and eye injuries and fire hazards.
  • Laser beams should not be directed at employees, and systems should not be operated in rainy, snowy, or dusty weather conditions.
  • Other safety limits include limiting diffused reflected light to 2.5 watts per square centimeter, preventing employees from exposure to microwave power densities above 10 milliwatts per square centimeter, and having removable panels and doors with interlocks that automatically reduce or stop laser emissions when the enclosure is opened.

Safety Standards and Exposure Limit for Workers: Laser Cutting Applications:

  • The Occupational Safety and Health Administration (OSHA) has established safety limits for laser equipment, categorized by power and hazard level.
  • Class III B lasers are moderate power, while Class IV high power lasers pose hazards to view, ignite materials, and produce air pollutants.
  • It is not appropriate to point the laser beam toward workers, and it is not advisable to run systems in wet, snowy, or dusty environments.Laser equipment labeling should indicate its maximum output, and Class IIIB or Class IV lasers should be enclosed in a Class I enclosure or have a Laser Safety Officer present.
  • Ideally, the laser unit should be set up above employees' heads.

Visit  blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune and our virtual locations at Delhi, Bangalore, Ahmadabad, Hyderabad, or Chennai locations.

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Analyzing Total Ownership Costs: Selecting the Right Clean Air Project Option

Total ownership cost
Total ownership cost

Analyzing Total Ownership Costs: Selecting the Right Clean Air Project Option

In the previous couple of blogs, we discussed planning and designing clean air systems, including choosing the right filtration technology and fan selection. Total ownership cost is a crucial parameter to consider, including filter technology, air flow capacity, running costs, filter replacement costs, blower capacity, and ducting length.

What is the total ownership cost?

Total ownership coat, a management accounting concept, helps determine the direct and indirect costs of a product or service over the long term to arrive at the correct decision while making decisions.

What is the total ownership cost of a clean-air system?

Total ownership cost for a clean air system consists of some parameters such as air flow capacity, filter efficiency, compliance with EMS, size of equipment, considered duct length, static pressure, blower capacity, cell configuration, total initial investment cost, running cost for 1 year, AMC charges per year, standby filter cell, replacement cost of the filter, any optional accessories, etc.

In short:

Total Ownership Cost concept for 3-5 years (installation cost + running cost + maintenance cost + replacement cost = Total Ownership Cost)

Consider a simple case study to illustrate this concept. A fume extraction system with a 45,000 CMH airflow capacity—three options based on different filtration technologies—is worked out.

Total Ownership Cost Scenario for

  • Electrostatic Precipitator Technology (ESP)
  • Cartridge Technology
  • Wet Scrubber Technology

You can read about the above 3 technologies in our previous blog article <a href="https://filter-on.com/2024/04/05/selecting-the-right-filtration-technology/" style a:link, a:visited { background-color: #f44336; color: white; padding: 15px 25px; text-align: center; text-decoration: none; display: inline-block; } a:hover, a:active { background-color: red; } here.

For example, we take into consideration the air flow capacity of 45000 CMH. Here is an illustrative calculation of the total ownership cost of the above 3 technologies, provided with the parameters.

Total Ownership Cost Structure
Parameters ESP Technology Cartridge Technology Wet type:Venturi Scrubber
Airflow Capacity 45000 CMH 45000 CMH 45000 CMH
Filtration Efficiency 95+/-2% for 0.5 micron and above particles It depends on media selection. Generally chosen cartridge: 99% for 1 micron or 0.5 micron for welding fumes 99% for 5 microns and 98% for 2 microns
Compliance with EMS Filtered air output is less than 5 ppm. Filtered air output is less than 5 ppm. Filtered air output is less than 5 ppm.
Size of Equipement Compact Larger than ESP system. The biggest of the three
Considered Duct Length Approx. 100 mtr. per system Approx. 100 mtr. per system Approx. 100 mtr. per system
Blower Capacity 50HP/37Kw 100HP/74.5Kw 150HP/112Kw
Total Initial (Basic) Investment Cost (Equipment, Ducting, and Installation) INR 60.16 lakh INR 76.31 lakh INR 104.81 lakh
Running Cost for 1 Year (considering 16 hours per day x 300 days and 10 Rs/unit) INR 17.76 lakh (per year) X 3 years = 53.28 lakh INR 35.76 lakh (per year) X 3 years = 107 lakh + compressed air charges INR 53.66 lakh (per year) X 3 years = 161 lakh + water charges
AMC Charges per Year (All Scope) Approx. Rs 6 lakh (for 12 visits per year) X 3 years = 18 lakh Approx. 1 lakh (for 4 visits per year) X 3 years = 3 lakh Approx. Rs 6 lakh (for 12 visits per year) X 3 years = 18 lakh
Replacement Cost Filter After 3 years, Rs 1.20 lakh for pre- and after filter replacement & After 5 years, Rs. 3 lakh for ESP filter refurbishment After 2 years, Rs 9.90 lakh N/A
Optional accessories like a VFD, PLC, motorized damper, spark trap, etc. INR 12.92 lakh INR 19.73 lakh INR 27.15 lakh
Total Ownership Cost for 3 Years 154.56 Lakh 215.94 Lakh 310.96 Lakh

Cost Breakdown Parameter-wise & Technology-wise:

Cost breakdown for total ownership cost is here as follows:

Total Ownership Cost Structure
Cost Parameters Cost Of ESP Technology Cost Of Cartridge Technology Cost Of Wet type:Venturi Scrubber
Installation Cost 60.16 lakh 76.31 lakh 104.81 lakh
Running Cost 53.28 lakh 107 lakh 161 lakh
Maintenance Cost-AMC 18 lakh 3 lakh 18 lakh
Replacement Cost 1.2 lakh 9.9 lakh 0
Optional Cost 12.92 lakh 19.73 lakh 27.15 lakh
Total Ownership Cost for 3 Years 154.56 Lakh 215.94 Lakh 310.96 Lakh

Total ownership cost - parameters wise breakup

Fig: Total ownership cost(Parameter wise breakup)

Total Ownership Cost Structure
Technology Total Ownership Cost
ESP Technology 154.56 lakh
Cartridge Technology 215.94 lakh
Wet/Venturi Scrubber Technology 310.96 lakh

Total ownership cost technology wise breakup

Fig: Total ownership cost(Technology wise breakup)

Understandings from the above example:

As per the above example of total ownership cost calculation about the 3 technologies, we can conclude that the ESP technology is totally beneficial in the long run as per the costing, as the total cost is very low; it’s only 154.56 lakh as compared to cartridge technologies 215.94 lakh and wet scrubbers 310.96 lakh for the period of 3 years.

Key takeaways from the above example:

  1. From the above example, you can see that the total cost of ownership of ESP technology is low as compared to the other two technologies.
  2. The total cost of ownership consists of several parameters that are very important, including air flow, blower capacity, initial cost, filter cost, cost of ducting, etc.
  3. The most important parameter of the clean air system is air flow calculation, so air flow rate is the most comparable factor to check which proposal is capable of solving your industrial indoor pollution problem.

Visit blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune and our virtual locations at Delhi, Bangalore, Ahmadabad, Hyderabad, or Chennai locations.

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Comprehensive Guide to Duct Design: Types, Velocity, Power, and Pressure Drop with 7 Practical Design Guidelines

Duct Deign Guide
Duct Design Guide

Comprehensive Guide to Duct Design: Types, Velocity, Power, and Pressure Drop with 7 Practical Design Guidelines

Ducting is a main and important component of any clean air system design. Ducting involves various parameters, including ducting type, required velocity, power consumption, and pressure drop. We will discuss all the above parameters in today's blog post, “Duct Design: Guide for Ducting Design of a Clean Air System,"  as well as a few guidelines for standard duct design. 

Duct Design: Types of ducting:

Ducting has two types:

  • Round Ducting
  • Rectangular Ducting

Duct type, such as round or spiral duct, is a type of steel pipe made from various materials like stainless steel, aluminum, copper, and galvanized steel.

Round ducts are more common in fume extraction and dust collection systems, whereas rectangular ducts are more common in air conditioning systems and fresh air ventilation systems.

Round vs. Rectangular

Why round ducting is preferred over rectangular ducting in air pollution control systems:

The main reason is that the dust accumulation inside round ducts is very low as compared to rectangular ducts. In rectangular ducts, dust keeps getting accumulated at the corners. This is not a good situation in any way because it creates a safety or fire hazard in the case of some industrial pollutants like aluminum dust and where there is a possibility of sparks or hot particles entering the duct. Other factors are:

  • A round duct has a low pressure drop.
  • Round ducting is also more rigid than rectangular ducting.
  • The round duct has a lower duct vibration drum effect than the rectangular duct.
  • A round duct has a lower noise level as compared to a rectangular duct.
  • Round ducting has less friction for the air to move around, so it tends to move faster and more efficiently as compared to rectangular ducting.
  • Round ducts work best with medium- to high-pressure clean air systems.

Duct Design :Duct Velocity and Sizing

Duct Velocity:

The air duct velocity, also known as air flow velocity, is a measurement of the air that moves through your clean air system's air supply and return grilles. This can be measured by either feet per minute (FPM) or meters per second (m/s).

Certain optimum ranges are recommended as per application; e.g., for dust collector applications, a range of 20–22 m/s is common so as to avoid dust deposition inside the duct. This velocity ensures that most of the dust particles are swept effectively up to the dust collector. In the case of welding fumes, this value is lower (@15–17 m/s), as it would need much less velocity to convey fumes as compared to dust.

CFM, which is “cubic feet per minute,” = velocity, which is shown in “feet per minute,” multiplied by the area, which is shown in “square feet.”

Duct Sizing:

Duct sizing is the most important factor in the design of a duct.

How is the duct size calculated then?

The Darcy equation reveals that reducing duct diameter increases pressure loss at a constant volume flow rate, while larger volume flow rates require larger duct diameters.

Duct Sizing Methods:

There are three important duct-sizing methods:

  • Equal friction method
  • Velocity Method
  • Friction Method
  • Static Regain

Duct Velocity and Pressure Drop

Duct velocity and pressure drop are important factors in a clean-air system. These factors influence airflow, duct velocity, and total pressures. Accurate calculations help ensure optimal airflow, comfort, and efficient system design. Excessively higher velocities than the recommended range would produce a very high pressure drop. Also, too little velocity will increase the size of the duct and, thus, the ducting cost.

Velocity and power consumption

Higher velocity leads to a higher pressure drop, and thus, you would need more power to overcome that pressure drop. This will increase the running cost of the system.

Duct Sizing: Increasing and Reducing Diameters

Increasing and decreasing diameters in duct sizing are based on the Darcy equation. The Darcy equation reveals that reducing duct diameter increases pressure loss at a constant volume flow rate, while larger volume flow rates require larger duct diameters.

Elbows, sharp bends, reducers, etc.

Elbows:

Elbow Design Guidelines

Fig: Principles Of Duct Design-Elbows(ACGIH Industrial Ventilation-23 Edition)

Radius elbows are recommended for rectangular ducts, while mitered elbows with turning vanes are suitable for medium- and high-velocity VAV systems. Short-radius elbows with splitters are recommended for medium- and high-velocity systems. Mitered elbows with turning vanes are used if necessary, but not for low-velocity systems.

Sharp Bends:

Avoid sharp bends or turns to make the air flow clear, because sharp bends or turns restrict the air flow speed in ducting.

The ductwork system utilizes various types of bends, including long radius bends with a gradual centerline radius, short radius bends with a sharper radius, and U-shaped bends like return bends. Mitered bends, offset bends, and bumper bends are used to change flow direction, redirect flow, and absorb shock or vibration.

Reducers:

Sharp-step-type reducers are to be avoided. Smooth tapering reducers should be considered. Also, ensure that the size of the duct is expanded prior to connecting branches and not after the connecting branch.

Dampers for balancing

Dampers are essential in CV (constant volume) systems, including self-balancing methods. The use of dampers ensures that we get the required air flow as per design at each branch.

7 Practical Guidelines for Duct Design:

Duct Enlargements1

Fig: Principles Of Duct Design-Duct Enlargements(ACGIH Industrial Ventilation-23 Edition)

Duct Enlargements2

Fig: Principles Of Duct Design-Duct Enlargements(ACGIH Industrial Ventilation-23 Edition)

  1. The general rule of thumb is that the less duct work you have, the cheaper it’s going to be. The fewer bends and elbows required are ideal.
  2. The blower needs to be less static, meaning a more cost-friendly exhaust blower, requiring less HP and energy consumption.
  3. Straight runs are best because they reduce wear issues and resistance in your duct system.
  4. Long-radius bends, curves, and turns are essential in creating airflow, reducing static pressure resistance and enhancing airflow by ensuring soft and delicate designs. .
  5. The static pressure generated during duct runs can significantly impact the velocity of the air, requiring careful consideration and management.
  6. The nature of open or larger-diameter pipe sizes can allow for more movement and less static pressure.
  7. Consult an expert like Filter On India for typical duct-carrying velocities based on dust density.

Visit blogs to learn more about the critical features of clean air system design and air pollution control systems created by Filter On India.

Filter On India has been working towards “Mission Zero Pollution” for the last 40+ years as a clean air solutions partner for industries. We specialize and have expertise in welding fumes, oil mist, coolant mist, dust collection, soldering, laser marking, laser cutting, plasma cutting, fumes in fastener manufacturing, ball point tip manufacturing, oil quenching, kitchen fumes, etc. Filter On has 70+ clean air solutions, so you can contact us for more information about our solutions. You can reach us through the web or visit us at our corporate office at Pune and our virtual locations at Delhi, Bangalore, Ahmadabad, Hyderabad, or Chennai locations.

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