Dust control protects environment.

A complete intelligent dust collector automation solution, with advanced diagnostics and Floor-to-Cloud connectivity.

A new solution for Dust Collector Monitoring and Control has been announced by Emerson. A wide range of industries—including cement, mining and metals, chemicals and plastics, food and dairy, power, utilities, and more—handle materials that generate significant amounts of dust and particulate emissions. Automating dust collection monitoring is an effective way to optimize filtration, ensure environmental compliance, reduce costly maintenance, and avoid expensive unplanned downtime.

This intelligent, easy-to-deploy solution also integrates seamlessly with existing plant automation systems, helping to extend dust collector equipment life and boost overall operational efficiency.

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.

Intelligent monitoring and control can significantly reduce maintenance costs and the total cost of ownership. Smart filter cleaning can minimise energy costs and compressed air consumption. Detecting and identifying failed filters helps avoid regulatory penalties. In addition, extending filter life by as much as one year can result in savings of up to $18,000. 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.

Recognising these needs across multiple industries, Emerson offers a portfolio of essential elements necessary 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 visualisation interfaces; and PACSystems™ PLC, I/O, and edge analytics.

“With this world-class and easily implemented solution, 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 Samuele Oliva, product marketing manager for dust collectors and alternative energy with Emerson’s discrete automation business.

Emerson’s standard dust collector monitoring and control solution combines these proven products and capabilities:

• Optimized 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.

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.

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Dust pulse technology control systems.

System provides superior monitoring, optimizing dust collector system performance and increasing uptime

Emerson’s new ASCOTM DPT Control System optimizes the performance and improves the efficiency of filtration and dust collector systems by providing accurate and reliable low-level particulate monitoring, early warning leak detection, enhanced cleaning control and real-time diagnostics. The connected system serves as a cost-effective, scalable and purposeful step toward a facility’s digital transformation. It is now available in Asia-Pacific, Europe and Middle East and Africa regions, with availability in the Americas by mid-2023.

Using traditional sensing technology, low-level leakage is hard to detect in environments with high operating pressure, high humidity or oil and steam. The advanced signal processing of the DPT Control System helps ensure accurate, low-level measurement and detection of particles of less than 1 milligram per cubic meter in harsh, high-pressure (maximum 7 bar) and high-humidity applications, like those found in the cement, power plant, incineration, finishing aluminum and chemical industries.

“The digital transformation of the process industry is underway and connected facilities around the world are seeing the valuable sustainability and operation cost reducing benefits that real-time monitoring and diagnostics deliver,” said Stephan Cocciardi, director of marketing and global strategic accounts with Emerson’s discrete and industrial business. “The sophisticated monitoring capabilities of the ASCO DPT Control System can help facilities detect issues and prevent problems that would otherwise waste energy and accrue unplanned downtime, resulting in a more efficient and reliable dust collection system.”

By closely monitoring dust collector systems in real time, the DPT Control System can help users locate and address leaks before they become issues, improving energy efficiency and compressed air consumption savings. The loop-powered sensor enables intrinsically safe monitoring of difficult-to-access points of the filtration system, including coil, diaphragm and filter bag. The system’s condition monitoring and predictive maintenance capabilities can improve system reliability and efficiency while reducing maintenance costs and unplanned downtime. Its superior linear output can help users track real-time particle emissions levels and meet emissions regulations.

In addition to monitoring, the DPT Control System optimizes the performance and uptime of dust collector systems of all sizes through efficient and reliable pulse-jet filter cleaning control. For facilities that use large baghouses, application-specific control algorithms can reduce pulsing frequency, which can extend filter life and reduce the amount of compressed air consumed. The control logic can maintain quite low and stable differential pressure during operation and automatically maintains differential pressure within ±25 Pa (±0.1 inch) of water column of set point while minimizing pulsing. This ensures consistent cleaning performance, maintains a proper filter cake and can reduce compressed air use by 15% to 40% over standard, on-demand cleaning and up to 90% over continuous. It also helps ensure consistent airflow to maintain production, ventilation and dust recovery.

The system provides extensive general filter pulse jet cleaning control modes, such as easily selectable pulsing patterns and a full range of basic timing modes. Modes include continuous, high/low, single cycle and cycle down.

The complete DPT Control System solution includes the DPT P150 Particle Monitor, DPT P151 Controller and P152 DPT Particle Sensor. 

* See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

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Valve for dust collector systems

ATEX certified series 353 pulse valve is ideally suited to challenging environments in the agricultural, grain, food, pharmaceutical, chemical, wood, plastics and cement industries

ASCO Numatics has introduced a 316L stainless steel version of its series 353 pulse valve for use in dust collector systems. Certified to ATEX Category II 2G/D Zone 1 + 2 for explosive areas, it has been introduced to meet the growing demand for valves for challenging environments in the agricultural, grain, food, pharmaceutical, chemical, wood, plastics and cement industries.

The valve has the same features as the existing aluminium version and is suitable for control with either remote ASCO pilot valves or an integral solenoid. The diaphragm pulse valve combines high flow, long life and extremely fast opening and closing to provide a reliable and cost effective solution. The valves are available as ¾”, 1” and 1½” threaded versions and can be mounted in any position without affecting their operation.

The series 353 pulse valve is part of a complete range of dust collector products from ASCO Numatics that includes power pulse valves, pilot valves, pilot boxes, sequential controllers, pressure differential modules, tank systems and air preparation equipment.