Global technology and software company, Emerson, has launched an automated solution for Dust Collector Monitoring and Control, which can integrate with existing plant systems to help extend dust collector equipment life and boost overall operational efficiency.
A wide range of industries – including food and beverage – handle materials that generate significant amounts of dust and particulate emissions. Automating dust collection monitoring is an effective way to optimise filtration, ensure environmental compliance, reduce costly maintenance, and avoid expensive unplanned downtime.
Dust collectors are designed to capture potentially harmful airborne particles and fumes, which is essential for protecting people and the environment, and for ensuring reliable equipment operation and maintaining environmental compliance. They vary in size, and are built to house filters, which must be monitored for performance, cleaned periodically with compressed air, and replaced when they fail or reach the end of their useful life.
Emerson’s new solution introduces intelligent monitoring and control to the equipment ecosystem, reducing maintenance costs by detecting and identifying blocked and failed filters.
Dust filters and pulsating solenoid valves play a critical role in many manufacturing and production operations, so preventing downtime and compressed air leakages can save thousands of dollars per hour.
By optimising pulse valve use with advanced algorithms and predictive diagnostics, Emerson's dust collector monitoring and control solution can extend valve and bag life, reduce compressed air waste, and protect dust collector equipment while avoiding costly maintenance and downtime.
Emerson also offers a portfolio of essential elements for high-performance dust collectors, including mechanical and automation products such as Asco pulse valves, pilot boxes, and air tanks; pressure and particle concentration sensors; basic sequencer controllers; Aventics air flow sensors; Movicon HMI/SCADA visualization interfaces; and PACSystems PLC, I/O, and edge analytics.
Emerson product marketing manager for dust collectors and alternative energy, Samuele Oliva, said the system is world-class and easily implemented.
“We aim to help our end users achieve greater operational efficiencies and gain valuable insights that reduce reactive maintenance, lower the risk of downtime, minimize energy consumption, and extend equipment life while addressing the knowledge gap by providing easily accessed information for operations personnel,” said Oliva.
Emerson’s standard dust collector monitoring and control solution combines the following products:
- Optimised control of pulse valves, including automated cleaning cycles of multiple filter lines
- Movicon.NExT SCADA enabling remote monitoring, alerts, reporting, and integration with existing systems
- PACSystems PLC controls and AVENTICS solenoids with built-in algorithm for efficient cleaning of multiple filter lines
- QuickPanel+ HMI, which provides real-time diagnostics and early warning of fault detection
- Scalable licensing based on pulse valve count (up to 500)
- ASCO P152 particle concentration sensors able to detect low dust levels and filter issues
- Differential pressure monitoring with Rosemount pressure sensors and optional 4-20 mA compatibility
- Compressed air, pressure, temperature, dust level and energy monitoring, plus predictive maintenance features
Emerson's Dust Collector Monitoring and Control system and related products are available through emerson.com. The company has a manufacturing and service facility in Melbourne for faster distribution and support requirements.
