Often in life, we try to go the cheap route, and sometimes it ends up costing us.  This is true when it comes to ductwork design on air filtration systems.   As we know the employee market in the manufacturing industry is very tight, everyone is trying to retain and recruit employees.  One of the factors that helps in this is air quality.

Some small changes to your filtration system can yield great returns – especially in system performance and cost of operation.

One common mistake is in the hoods or lack thereof at the source of capture.

The most common and least expensive of all hood configurations is the “raw edge hood.” It is just an open duct which stops near the source of the smoke. Hood design just doesn’t get much simpler than this approach.

Raw edge hoods, while very simple to produce, provide the poorest performance in collecting contaminants at the point of generation. This hood configuration pulls air not only from in front of the duct opening but, unfortunately, also from behind the hood opening, which makes it inefficient. This configuration also creates turbulence that, depending on airspeed, can effectively make an 8” duct equivalent to a 6” duct because of the air being compressed as it comes around the edge of the duct. (see drawing below) It also can contribute to increased energy losses and a potentially larger fan. This hood configuration option is less than optimal from a total cost of operation perspective.

There are many hood options, but one that is simple and very cost effective is the bell-mouth.  It is so named because its tapered shape resembles that of a bell.

The bell-mouth shape allows the maximum amount of air to be drawn into the duct with minimum loss. It has a flange style piece that prevents pulling air from behind the duct opening and the low turbulence of the spun bowl entry profile.  With these attributes, it not only helps bring more volume of air but also helps with the direction that the air is pulled from.

In summary, if your factory is hazy, take a look around.  Can you see where the smoke or mist is not being captured?  Are there ducts that just stop over the parts bin that can have a bell-mouth or hood added?  Are there parts of the machine the can be enclosed?  There may be some small changes that can save you large expense and help your employees stay healthy.

Thanks for Reading,

The Bee Clean Team

847-451-0844

contact@beecleanspecialties.com

 

2018 has been a blockbuster year for the manufacturing sector and this quarter has been no exception. The Industry Supply Managements (ISM) Manufacturing report released this month showed factories continuing to grow and the decade-old expansion holding up into the second half of 2018.(1) Manufacturing outputs also continued to rise. The sharpest increase occurred this month with year-on-year outputs rising to 3.1%. This was the highest since June 2012.(2).

These results show the optimism currently in the industry. As an integral part of the manufacturing industry, we see these results first hand. Our customers are adding to their production capabilities and workforce’s with great stride. Remember to maintain your air filtration equipment to avoid falls in productivity and employee complaints. At Bee Clean, our technicians are always ready to solve your air filtration needs.

 

Thanks for Reading,

The Bee Clean Team

847-451-0844

contact@beecleanspecialties.com

 

Web Source:

1. The Industry Supply Managements (ISM) Manufacturing report, https://www.industryweek.com/economy/us-factory-gauge-jumps-14-year-high-orders-jobs-climb (accessed September 28, 2018).
2. Manufacturing Outputs, https://tradingeconomics.com/united-states/manufacturing-production (accessed September 28, 2018).

Ever wondered how your electrostatic precipitator, also known as electrostatic air cleaners, works? The science behind it and a short history of the technology are below.

In 1824 M. Hohlfeld a mathematics teacher in Leipzig, Germany, first described the precipitation of smoke particles by the electricity. (1) In 1908 the first successful patent for a commercial process was applied for by American chemist Frederick Gardner Cottrell. (2) By 1929 a young research engineer named Penney created an experimental precipitator for his home to combat the grime of Pittsburgh. He quickly filled a quart milk jug with black, powdery rubbish from the air. Since then the technology has evolved to be used in many residential and commercial applications. Capable of capturing particles as fine as 2.5 microns it still stands today as the most efficient and effective way to remove airborne particles.

The electrostatic precipitator works by applying energy only to the particulate matter being collected, without significantly impeding the air flow. This is a two-stage process by first drawing oil mist or smoke into the air cleaner, it goes into the ionizer which has 7 or 10 mil tungsten wires with 8 – 11,000 Volt DC on them, that gives the smoke and mist particles a static charge. Then the charged particles go into the collection cell which has a series of parallel plates, every other one is ground, and the one in between has 4 -7 KV DC (voltage varies depending on brand and plate spacing) this pulls the charged particles out of the air-stream. A similar example from everyday life would be rubbing a balloon on your hair which gives it a static charge; then it will stick to a wall.

Watch the short video below for a visual explanation of the process.

We hope you enjoyed this brief explanation of Electrostatic precipitators and the technology behind it. Our experienced technicians are always ready to help you maintain your precipitators and solve existing air quality problems.

Thanks for Reading,

The Bee Clean Team

Contact Us!

Web Source:

1. Electrostatic Precipitator, https://www.britannica.com/technology/electrostatic-precipitator (accessed August 28, 2018).
2. Electrostatic Precipitator, https://www.britannica.com/technology/electrostatic-precipitator (accessed August 28, 2018).

 

The easiest way to tell if your electrostatic air cleaner (EAC) needs cleaning is when you see smoke or oil mist blowing through. At this point, when you can see the visible plume, it is too late, your air is now hazy, the machine operators are complaining, and your blower is getting dirty. EACs collect the smallest particles that go deepest into your lungs but they are often not visible to the human eye, so your air cleaner can be blowing smoke through before you notice it.

So how can you check your EAC and catch it before smoke is blowing through?

There are a few things you can check:

• Pull out the collection cell, they start to get dirty on the leading edge, towards the intake side. As they get dirty, they collect farther and farther back on the cell plates. You want to clean them before it is dirty all the way back preferably catch it at about three-quarters of the way back. On a double pass or tandem pass EAC, check both sections, sometimes cleaning the first pass more often can extend the life of the second pass.
• Pull out the ionizer, some models this is one piece with the collection cell, and check the ionizer wires (or spikes on some brands) to see if they are dirty. If the wires have build-up on them, it can insulate the charge so that the smoke or oil mist does not get charged. If the smoke and oil mist does not get a charge, it will not get collected in the collection cell. Also, on the ionizer check the high voltage insulators, if these are dirty, depending on what you are collecting, they can drain down the voltage making the air cleaner less efficient.
• Pull out the after-filter, this is a one-inch aluminum mesh filter that most brands have after the collection cells. If the after-filter is dirty, it is time to clean. If your EAC is functioning correctly and service at proper frequency this filter will remain clean.
• Most brands of EACs have an indicator light. This light indicates that the collection cells and ionizers have the correct high voltage. If this light starts to flicker or goes off it is past time for maintenance. When this light goes out, service is needed right away.
• Lastly, you can pull out the pre-filter, this usually is not a problem unless it restricts the air flow. The prefilter is often a one-inch mesh filter similar to the after-filter but comes before the ionizer. The prefilter can also be two inches thick, or some models use an impingement baffle as well. If you hold the prefilter up to a light and can see light through the filter, it is usually ok. The pre-filter is typically only a problem if you are collecting a heavy particulate, most smoke or oil mist applications it will not be a problem.

 

At Bee Clean Specialties, we look at all these points when helping our clients determine the correct cleaning frequency. To have us help you with your air quality call us today at 888-451-0844 or click on the chat button.

Industrial and Commercial Electrostatic Industry Terms

ACCELERATION LOSS: How much energy that is required to accelerate the air to induce airflow at the entry of a system.

ACFM: Actual Cubic Feet per Minute of gas volume at any point of a system. This is used as a basis in rating Fans.

ABSORPTION: The process by which one thing absorbs or is absorbed by another.

AIR CLEANER: A device for filtering airborne particles of dusts, gases, fumes and smoke.

AIR FLOW: The flow of air.

AIR QUALITY STANDARDS: The acceptable level of a concentrated pollutant that is permitted in an atmosphere to avoid detrimental effects.

AIR POLLUTION: The presence of a gas, fume or particulate matter either alone or in conjunction with each other in an atmosphere which has harmful or poisonous effects.

AIR VELOCITY: An airstreams rate of speed, normally measured by fpm (feet per minute).

AMBIENT: Immediate surroundings or vicinity, not ducted to the source. AKA FREE AIR.

AMCA: Air Movement and Control Association

BACKDRAFT DAMPER: Damper that is used in a system to relieve air pressure in a given direction.

BAROMETRIC PRESSURE: A measurement of the pressure of an atmosphere.

BLOW THROUGH: pollutants that pass through a collector as a result of heavy loading or high velocity.

CAKING: When a substance hardens to the surface of an object when dried.

CAPTURE VELOCITY: The amount of air velocity required to overcome opposing air currents and capture the contaminated air.

CARTRIDGE FILTER: A method of collecting air borne particulates by use of pleated cellulose, synthetic fibers or a combination of both in a cylindrical shape.

CENTRIFUGAL COLLECTOR: Any system that uses centrifugal force to remove particles from an air stream.

CFM: Cubic Feet per Minute.

COLLECTION: The removal of airborne pollutants from an atmosphere. A successful system must include both the capture and collection of airborne pollutants.

COLLECTION CELL: A metal cell within an electrostatic precipitator where the particle collection occurs. Both charged and grounded plates are required in the process.

COLLECTOR PLATE: A portion of the collection cell used to attract and retain a particle from the air.

CONTAMINANT: Any material or gas, fume, vapor or particle that pollutes an atmosphere.

DAMPER: A mechanism used to regulate airflow throughout a system.

DUST: Fine, dry powder consisting of tiny particles that are the result of operations or actions.

DUST COLLECTOR: A system that is used to extract airborne impurities that are a result of industrial and commercial processes.

DWELL TIME: The length of time the air takes to pass through an air cleaner.

EFFICIENCY: This term refers to the ability of an air cleaning system to remove airborne particles.

ELECTROSTATIC PRECIPITATOR: Electrostatic air cleaners (EAC) are a high-efficiency air cleaner that achieves up to 99.3% collection of particles at .3 µm. The air cleaner contains two elements. The ionization section and a collecting plate section.

EMISSION: Release of pollutants into the air from a source.

ENTRY LOSS: The loss of pressure in a system normally caused by air flowing into it.

EPA: Environmental Protection Agency.

FAN: A machine that moves a continuous volume of air.

FILTER COLLECTOR: A filtration system for removing particulate matter. Commonly referred to as a bag collector.

FPM: Feet per minute, typically about the movement of an air flow.

FUME: A gas consisting of dispersed liquids or solids which consist of particles smaller than 1 micron.

GAS: A state of matter that is an airlike fluid substance which expands freely to fill any space available.

GROUND ELECTRODES: Vertical plates separating ionizers forming the electrically grounded element for the ionizing field that also contain and direct air particles during the ionization process.

HEPA FILTER: High Efficiency Particulate Air Filter

HERTZ: Frequency measured in cycles per second

HOOD: A shaped inlet designed to capture contaminated air and transport it into the exhaust duct system.

HORSEPOWER: An index that refers to how much work a machine can perform in a given period of time.

INDICATOR LIGHT: The light on an electrostatic air cleaner that shows whether the ionizer and collection cell have the correct voltage. These can be red, orange or green but all mean that it is functioning correctly if lit.

IONIZER: The portion of an electrostatic air cleaner that places a positive or negative charge on a particle.

MAKE-UP AIR: The process of replacing exhausted air through a ventilation system.

MERV: Minimum Efficiency Reporting Value and is in accordance with the ASHRAE 52.2 test method.

MICRON: A unit of length equal to one-millionth of a meter.

MIST: Liquid droplets that are less than 10 microns in size and are suspended in the air.

NOISE CRITERIA: A method for the design architect to specify the maximum permissible sound power level.

NON – ATTAINMENT AREA: An area where the atmosphere hasn’t reached hasn’t yet reached the National Ambient Air Quality Standards as defined by the CAAA.

OSHA: Occupational Safety and Health Administration.

OZONE: A compound that consist of three oxygen atoms. This is the common compound behind smog and can be considered dangerous to the lungs and natural elements.

PARTICLE: A small, discrete mass of solid or liquid material.

PARTICULATE MATTER: Any solid or liquid material in the atmosphere.

PLENUM: An enclosure that is typically used as a pressure equalizing chamber.

PM10: This term refers to the amount of particulate matter under 10 micrometers in diameter that is suspended in the air.

PPM (PARTS PER MILLION): The number of parts of a given pollutant in a million parts of air.

PREFILTER: A filter in electrostatic precipitators that has two common uses. First is to capture large particles to avoid rapid loading and second to evenly distribute the air for proper collection.

POWER SUPPLY: An electrical device used in electrostatic precipitators that converts AC line power to high voltage DC Power for the Ionizer and collector cells.

SOURCE CAPTURE: A term used to when an air cleaning system is designed to capture pollutants directly from a process or machine.

SMOKE: An aerosol particle suspended in the air which can be solid or liquid. Typically, smaller than 1 micron in diameter.

TANDEM PASS: An air cleaner that has a second set of ionizer and collection cells, to in crease the efficiency when there is a heavy smoke load, also know as Double Pass.

VAPOR: A substance in gaseous form.

VENTILATION: A process of removing or adding additional air by natural or mechanical means from or to a space.

VOLT: A unit of electrical potential or pressure. 110 or 230, 460 volts are normally found in the US.

What is Particulate Matter (PM) Pollution?

Particulate matter (PM) pollution is defined as any solid or liquid material in the atmosphere. PM pollution includes PM10 and PM2.5. PM10 are all inhalable particles that are 10 micrometers in diameter and smaller. PM2.5 are the finer inhalable particles that are generally 2.5 micrometers in diameter and smaller. While we are focusing on PM pollution from manufacturing sources in this blog there are many other sources of PM Pollution. Construction, power plants and even forest fires omit PM Pollution into the atmosphere. In Manufacturing these submicron particulates can be visible to the naked eye if larger than 7 micrometers. The smoke plumes seen in the air are made up of these particles. Some of the smaller particles are not visible to the naked eye and must be measured by a particle counter. The diagram below shows a size comparison for PM Particles.

How does Particulate Matter (PM) Pollution effect you?

Employers must put safeguards in place to protect their employees from PM Pollution. These particles are considered the most dangerous of lung damaging pollutants. They can penetrate the deepest part of your workforce’s lungs without their knowledge and can eventually enter their bloodstream. These airborne particles can disrupt the manufacturing process by preventing machinery from running smoothly which then increases downtime. Finished parts can also be contaminated from PM pollution if it’s not properly contained.

How to solve Particulate Matter (PM) Pollution

While PM Pollution can be alarming for both the employee and employer there are ways to contain these harmful particles. The most efficient way to extract these particles in most manufacturing facilities are electrostatic precipitators. This powerful high-efficiency air cleaning technology can achieve a particle collection of up to 99.3% at .01 micron. Electrostatic air cleaners capture these smallest particles which go deepest into your lungs. An interesting fact to consider is a particle that is 2.5 micrometers in diameter can take up to 3 days to settle on a surface from being airborne.  Therefore, you can have existing equipment for filtering these particles out of the air but still have visible smoke plumes. We have 40 years of experience working with manufacturers to safeguard their employees’ health and maximize their businesses output and are well suited to help you diagnose your existing electrostatic equipment and recommend the needed changes. We are always willing to help. You can Contact Us here or give us a call (847)451-0844 to set up a consultation.

Thanks for Reading,

The Bee Clean Team

The Manufacturing sectors outputs are increasing, and optimism is continuing to grow amongst manufacturers. We have been able to witness first hand the recent growth in employment as manufacturers take advantage of growth opportunities. According to Industry Week last month the Labor Department reported there were 12.6 million people employed in the manufacturing sector, this is the most since 2008. During periods of increased economic growth, Human Resources Departments can face some challenges as well. Below are the most critical ones to consider.

Employee Turnover

One of the leading causes of an employee leaving a position is poor working conditions. Air quality in manufacturing is the first way to combat poor working conditions. The studies are many of the effects that air quality have on employee morale and keeping a positive workplace. Employees now have a choice when it comes to where they will be employed, and investments in your air quality equipment and maintenance will pay dividends toward your working conditions and maintaining a positive workplace.

Employee Productivity

In a study from 2008 Researchers calculated that the improvements in air quality between 1999 and 2008 saved the US manufacturing industry $20 billion a year in productivity or 2.6% of the industry’s wage bill. Those numbers are staggering and point up how investments in your air quality will directly affect your bottom line and help you realize that poor air quality makes your employees perform worse in their job duties. Not only do improvements in air quality save you dollars regarding employee productivity but they also keep you compliant with OSHA and EPA regulations.

Recruiting

Currently, when you set out to recruit employees, you must be conscious of the increased demand for the manufacturing workforce. Some things to consider here are workplace attitude and the physical appearance of your factory. Both are a direct result of your industrial air cleaning equipment. In the picture below, you see an extremely clean and well-maintained facility. It also helps you understand how this visually affects a future employees decision to join your workforce.

With more than 40 years in the industry working with industrial electrostatic applications, we are well suited to diagnose and help you improve your existing equipment and new applications as well. We wish you the best success in your Human Resource department. Feel free to reach out for help with your air quality we are always glad to help.

Thanks for reading,

The Bee Clean Team

contact@beecleanspecialties.com

(847)451-0844

 

Understanding Unducted Air Cleaner Systems

There are two main ways that Electrostatics air cleaners capture air, source capture systems and unducted systems, also known as ambient or free air. Source capture still stands as the most recommended and efficient way to capture air but in some cases our customers find an unducted capture to be the best solution for their operations.

Success with unducted systems is created by establishing a recirculating air flow in your space. The airflow is established by having the clean airflow from one precipitator blow across to the intake of the next precipitator which collects the rising pollutants along with it. A key point to remember is the overall performance of the unducted system will come out of the ability to properly create a recirculating air flow. Two examples of air flow patterns are below. These are shown using Smog Hogs SG-4-T models.

Unducted systems must be designed properly to see effective results. Some design considerations to consider are the size and shape of your space, existing air and ventilation equipment, having the right filtration equipment to match your design specifications and how many air changes per hour. Below is a graphic showing the recommended air changes per hour. Another way to determine how frequently to change the air over is to notice how soon after starting your machines the room is too smoky.If it is too smoky at 10 minutes, you need to change the air more than six times an hour. In other words, if you turn the air over six times an hour you will always have 10 minutes of smoke in the air.

With our extensive experience in the field of electrostatic precipitators we can take you through the process of getting your industrial applications set up for maximum efficiency. Credit is due for some of the information and graphics from this article from the Industrial Air Filtration & Technical Reference guide produced by United Air Specialists. For help with your specific application give us a call at (888)451-0844 or reach out to contact@beecleanspecialties.com.

Thanks for Reading,

The Bee Clean Team

Commercial Kitchen Service

Bee Clean Specialties has been helping restaurant operators in our service area with their Electrostatic Precipitator and activated charcoal filtering needs for the last 15 years. Electrostatic Precipitators remain one of the most efficient technology when filtering kitchen exhaust. Electrostatics in restaurants work the same as in industrial applications and are normally placed at the point of exhaust. When the contaminated air enters the ionizer it is electrically charged, causing the grease and smoke to be collected in the reusable collection cells.

Restaurant operators install electrostatic precipitators for several reasons. One being local regulation. Another reason is landlords tenant requirements. If you are running your restaurant from a leased space your landlord may require an electrostatic precipitator to clean the air so as not to disturb the other tenants.

Many of our restaurant clients have an activated carbon filter section after the electrostatic filter. Activated carbon absorbs vapors and odors from the restaurant and will reduce complaints of nuisance smells. We have the ability to test your activated carbon to check what percentage is spent. This test will save you unnecessary filter change outs and reduce cost.  

Bee Clean is well equipped to service your restaurant application quickly and efficiently. Give us a call for a quote on servicing your existing equipment or for help with designing your commercial operation.

Thanks for reading,

The Bee Clean Team

(888)451-0844

contact@beecleanspecialties.com

 

Electrostatic air cleaners are considered a green technology. With 40 years in the industry, we have been able to see firsthand the advantages of these air cleaners.

Three reasons this technology is considered green are listed below.

1. High efficiency

Electrostatic air cleaners (EAC) are a high-efficiency air cleaner that achieves up to 99.3% collection of particles at .3 µm. When electrostatics reach their capacity, they continue to pull air from the source and into the air above which keeps the operators working free from the dangers of airborne particles whereas when media units reach capacity in the same application they lose the ability to pull air from the source which inhibits the operators’ ability to work. 

2. Low energy use

Electrostatic air cleaners (EAC) only use about 1 HP of fan energy per 1000 cfm. Comparative media filter competitors would use about 3 HP per 1000 cfm. This reduced low energy use will positively impact your bottom line financially and provides a positive environmental impact as well.

3. Reusable collection cells

All brands of electrostatic air cleaners (EAC) have reusable collection cells and with proper care can have an average lifetime of 30 years. This is considered green because it saves oil-soaked media filters from being landfilled. For example, in a case study of one of our clients who use media filtration units, they throw an average 2,320 pounds of soiled filters away a year. If you multiply that by the average 30-year lifespan of an electrostatic collection cell that is 69,600 pounds of filters being sent to the landfill. The last benefit is electrostatic cells are made of 100% recyclable parts.

Thanks for reading,

Bruce McAbery | Bee Clean Specialties LLC