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Dust Collectors for Thermal/Flame Spray

Sizing Recommendations

With Thermal Spray applications, proper information gathering of the specific application is crucial since there are many different types of processes and material coatings, most all of which will react differently inside the dust collector. Although there are different powders used in plasma spray for example, the process results in generally spherical shaped particulate and consistent in size at around three microns making it fairly easy to capture.

Over the years, we tried several types of dust collection equipment on EAW spraying. However, all previous attempts at extended filter life (more than six months) failed until we installed a high efficiency "Gold Series®" cartridge collection system manufactured by Farr, Arkansas. At the time of this writing, the Gold Series collector is still performing exceptionally well without a filter change after about a year and a half.
-David Drozd, Pamarco

With the Camfil Farr APC Gold Series Vertical Cartridge Collector, plasma spray and powder applications are generally sized around 1:1 air-to-cloth ratio (A/C) with HemiPleat Fire Retardant cartridges. Electric Arc Wire (EAW) Spray on the other hand has proven to be a real challenge. This dust is very fine (mostly sub-micron) and is inconsistent in shape. This seems to be true of the process itself no matter what type of wire is being used.

The Gold Series is usually sized at 0.5:1 to 1:1 A/C for EAW spray. At times you will be faced with collecting both types of dust. The more conservative A/C ratio is recommended and will provide the cartridge longevity that is required in the industry. In general, when collecting aluminum off-spray a conservative A/C is also recommended, usually around 0.50:1. It is imperative that we understand not only the type of material being sprayed but also the type of spraying be conducted. A dust collector can not be properly sized for Thermal Spray applications without this information. Because of the combined challenge of the different spray processes themselves along with the generally fine particulate that is involved, dust collectors are rarely sized above 1.5:1 for any Thermal Spray applications with the majority being between 0.50:1 and 1.2:1 A/C ratio.

GS32 on a Thermal Spray application GS32 on a Thermal Spray Application

Additionally, staggered channel baffles in the Gold Series inlet plenum should always be used for Thermal Spray applications. The baffles protect the cartridges from direct impingement and effectively directs the material into the hopper area for discharge.

It is also important to note that certain hazardous powders and metals (such as beryllium and chrome) will require safety after-filters whether returning the air back into the work facility or discharging to atmosphere. Please work with Camfil Farr APC application engineers to insure the correct information is understood and proper sizing is accomplished.