Dust Collectors for Thermal Spray / Flame Spray

Flame Spray

Because of the various types of thermal spray applications and their effects on the operation of dust collectors, it is important to identify your specific thermal spray operation. Each process involves different shaped and sized particulate along with varying loads. Additionally, strict safety procedures need to be addressed as almost all thermal spray operations can be explosive and/or flammable.

Safety Considerations

The potential for fire and explosion is very real when dealing with Thermal Spray and dust collectors. It is imperative that Farr APC be contacted for proper explosion venting and other safety concerns. Explosion vents, sprinkler kits, flame retardant cartridges and possibly spark traps all need to be addressed during the proposal phase of the sale.

Thermal/Flame Spray before Gold Series turned on

Thermal/Flame Spray after Gold Series turned on

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.

With the 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 commended, 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 size 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.

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 Farr APC application engineers to insure the correct information is understood and proper sizing is accomplished.

GS 120 on Thermal Spray

Gold Cone® Cartridge

Camfil Farr Gold Cone cartridges have an expanded capacity due to the patented inner Gold Cone. This inner cone increases media area and provides uniform dispersion of back-pulsed air. It also opens up more useable space for air flow in the filter. More Info