Applications that can create dangerous dust

  • Electric arc wire (EAW) spraying
  • Flame spray powder or wire
  • Electric arc spraying
  • High-velocity oxy-fuel (HVOF) and high-velocity air-fuel (HVAF)
  • Plasma spraying
  • Vacuum plasma spray
  • Cold spray

Different thermal spray applications have different effects on dust collectors because each application involves differently shaped and sized particulates and varying loads.

Safety Considerations

The potential for fire and explosions is very real when collecting dust from thermal spray applications, as certain types of metal can be explosive and/or flammable. OSHA and NFPA require strict safety procedures when working with metals that create combustible dust.  Also, certain hazardous powders and metals (such as nickel and chromium) will require safety after-filters when discharging to the atmosphere. Camfil APC experts can help you select a safe and cost-effective dust collection system and the required explosion protection equipment. This equipment might include explosion venting, flame retardant cartridges, and spark traps.

Benefits of Farr Gold Series® Dust Collectors

  • High entry cross flow, inlet eliminates upward can velocities that can hold fine powder up in the filters, reducing re-entrainment of the fine particles.
  • High-efficiency filters stop 99.99% at 0.5µ of the dust!
  • Specially treated filter media repels the fine particles for lower pressure drop and long filter life.
  • Gold Cone® provides 25% more media for long service life.

Sizing Recommendations

With thermal spray applications, it's crucial to gather the proper information for each application. There are many different types of processes and material coatings, and most of these will react differently inside the dust collector. The thermal spray process typically produces spherically shaped particulates that are consistent in size at around three microns and fairly easy to capture. For these applications, Camfil APC generally sizes dust collectors at a conservative air-to-cloth (A/C) ratio with HemiPleat® fire retardant cartridges. Electric arc wire (EAW) spraying applications are much more challenging because they generate very fine dust (mostly sub-micron) that is inconsistent in shape.  Camfil APC application engineers understand all of these factors and take them into consideration to ensure that each dust collector is sized properly.

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 "Farr Gold Series" cartridge collection system manufactured by Farr, Arkansas. At the time of this writing, the Farr Gold Series collector is still performing exceptionally well without a filter change after about a year and a half.

-David Drozd, Pamarco