Every Breath We Take – The Life Cycle Cost of Air Pollution

A new report issued by the Royal College of Physicians states that the health impact of Britain’s air pollution is far more serious than previously thought. It states that UK air pollution is the cause of up to 40,000 premature deaths a year. The report also concludes that in addition to the negative effects on health, air pollution also creates very high costs for society and business.

The report highlights the fact that air pollution causes damage throughout lifetime, from a baby’s first weeks in the womb all the way through to old age. For example, lung function naturally develops throughout childhood, now there is clear evidence that long-term exposure to outdoor air pollution suppresses this process. Air pollution is also linked to the development of asthma and cardiovascular diseases in adults (heart disease and strokes). The most vulnerable groups include people in low income areas, those with other health issues such as obesity, heart and lung conditions as well as the elderly and the young.

The report presents an historical overview of air pollution. The London smog of 1952 also referred to as the “Big Smoke” killed 12,000 people. Today’s older generations who were brought up in the 1940s-1950s were exposed to soot and sulphur dioxide from coal burning, in the 1960s-1980s carbon monoxide and emissions from leaded petrol were the pollutants of concern. Today’s children inhale nitrogen dioxide and sub-micron particles, so called PM1 from diesel-fueled vehicles.

The fact that air pollution and climate change are intertwined is also underscored in the report. In other words, many strategies to decrease air pollution are also effective in slowing down climate change. One way to achieve these dual goals is to use energy more efficiently.

What can we do as individuals to protect our health and the environment in a sustainable way? Although it is difficult for us to limit our exposure to outdoor pollution, we can do a lot to improve indoor air. Since we spend most of our time inside buildings, indoor air quality is crucial to our health. Pollution found inside a building is a cocktail of outdoor air pollutants and indoor pollutants such as, tobacco smoke, volatile organic compounds (VOCs) and biological pollutants.

Historically; research, government recommendations and consequently public awareness has been limited to airborne particles labelled PM10 and PM2.5 (smaller than 10 microns and smaller than 2.5 microns). However the latest research now indicates that the focus should be put on even smaller particles, those that are 1 micron or smaller in diameter. This is because smaller particles pass the natural barriers in the human body such as nasal hairs and mucus films in the upper respiratory tract and penetrate deep into the fine structure of the lungs where they enter the bloodstream and get distributed around the entire human body.

It is noteworthy that a new international standard for classification of air filters (ISO16890), due for ratification later in 2016 will require that the efficiency of the filter against PM1 be assessed and reported. Camfil strongly supports this development. It is a certain way to ensure appropriate high efficiency air filters are used to provide protection of human health from very fine particles.

Many industry articles on how proper dust and fume collection techniques can protect you, your employees and your business in a factory environment can be found here.

Exploring the Congressional H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013

The H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013 was referred to the subcommittee on Workforce Protections in Congress on 4-23-2013.  While the important urgency of worker safety regarding combustible dust is growing everyday, Congressional members have not brought the bill H.R.691 to a roll call.  Mr. George Miller of California  Mr. Barrow of Georgia introduced the bill and have faced lobbying groups and other obstacles slowing the bills chances of passage.  

The bill will require the Secretary of Labor to issue an interim occupational safety and health standard regarding worker exposure to combustible dust, and for other purposes.  After extended research Congress found that an emergency exists concerning worker exposure to combustible dust explosions and fires, and there is a significant risk of death or severe injury to workers employed at facilities where combustible dusts are present.

   The CSB recommended that the Occupational Safety and Health Administration (OSHA) issue a standard designed to prevent combustible dust fires and explosions in general industry, based on current National Fire Protection Association (NFPA) dust explosion standards.  The recommendation was released in November.
             
After 3 catastrophic dust explosions that killed 14 workers in 2003, the Chemical Safety and Hazard Investigation Board (CSB) issued a report in November 2006.  The report identified 281 combustible dust incidents between 1980 and 2005 that killed 119 workers and injured 718. ``Combustible dust explosions are a serious hazard in American industry'' according to The CSB.  A quarter of the explosions occurred at food industry facilities, including sugar plants.

To read the full: H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013 bill.

To find out more about combustible dust safety: Is Your Factory Safe From A Dust Collector Explosion?

Preliminary First Draft of the Proposed 2015 Edition of NFPA 652 Standard

The National Fire Protection Association (NFPA) has released the Preliminary First Draft of the proposed 2015 edition of NFPA 652. The standard will provide the basic principles of and requirements for identifying and managing fire and explosion hazards of combustible dusts and particulate solids. The standard will provide the user with general requirements and direct the user to the appropriate industry or commodity-specific NFPA standard for additional requirements.

The document establishes the basic principles and requirements that shall be applied to all facilities where combustible dusts or particulate solids are present. Where an industry or or commodity specific NFPA standard exists, its requirements shall be applied in addition to those in this standard. The proposed 2015 edition of NFPA 652 is very detailed in explaining specific definitions of all items contained in the document and applications where the standard will be applied.

You can read the entire document and learn even more at the links below.

Proposed 2015 Edition of NFPA Standard 652

National Fire Protection Association

Industrial Dust Collectors and Fume Collection Equipment

Article: Workplace Safety and Health Topics

A recent article exploring combustible dust explosions and the fatalities of first responders published by the CDC (Centers for Disease Control and Prevention) details statics and information on specific incidents.  We previously discussed this topic and feel the importance of prevention and education deserves even more attention. 

An average of 100 fire fighters are being killed while responding to fires and explosions.  The National Institute for Occupational Safety and Health (NIOSH) displays a listing of all investigative reports in a state by state map format.  We highly recommend reading each incident report as they explain in detail the dramatic incident with the source listed and the deaths associated.  Each incident is caused by varying combustible dust sources, such as metal dust, grain dust, coal, and wood dust.  Grain dust explosions have been on the rise with frequent coverage resulting in injuries and deaths. With most crops being harvested this time of year, the coverage could increase. 

Below is a listing of all links associated with the article.

CDC (Centers for Disease Control and Prevention)
National Institute for Occupational Safety and Health (NIOSH)
Listing of all reported incidents in an incident report.
You can visit this website for dust collection solutions and for information gathering.

OSHA Firefighting Precautions at Facilities with Combustible Dust

Often the first responders are at an immediate disadvantage upon arriving at a combustible dust explosion and/or fire.  This week OSHA released a booklet outlining safety procedures for emergency responders who may experience fires and explosions caused by combustible dust.

"The primary purpose of this document is to protect emergency responders from harm by giving them a framework for gathering the necessary information prior to an emergency and converting it into safe operating procedures.  In this document, emergency responders include firefighters, fire brigade members, hazardous materials teams, and others who might be called upon to respond when a fire or explosion occurs."states the OSHA booklet.

The booklet explains combustible dust explosions and how they occur.  Preparation that can be made before a response and precautions that can be made during an emergency response are detailed.  Another concern for first responders is the proper use of fire extinguishers, hose stream, equipment compatibility, and ventilation that are used.  The OSHA document details combustible dust and the reactions of usual fire fighting chemicals.  In some incidents the combination of explosive dust and water can escalate the incident resulting in injury or death.

Ventilation is a widely used practice by firefighters to remove heat and smoke, but can have catastrophic consequences when combustible dust is involved.  Actions such as appropriate power shutdown, safety procedures and normally used tools that can ignite combustible sources are addressed.

With more than 130 workers killed and 780 injured in combustible dust explosions since 1980, the booklet should immediately impact the safety concerns of emergency responders, workers and employers.

Links:
To download the complete booklet:  "OSHA Firefighting Precautions at Facilities with Combustible Dust".
To learn more about "Combustible Dust Collection"
Website: Occupational Safety and Health Administration

Article: 10 Ways A Dust Collection System Can Contribute To Your Plant’s Sustainability

A dust collector is designed to clean a factory of dust and fumes, thus making it fundamentally green.  By designing a dust collection system properly you can contribute to sustainability in many additional ways. An article appearing in Green Manufacturer magazine titled "10 Ways a dust collection system can contribute to your plant’s sustainability" written by air pollution control expert John Dauber, gives an easy overview in helping increase and maintain sustainability.

Make sure that the dust collector is compliant with the new U.S. Environmental Protection Agency (EPA) and National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6x regarding weld fumes and other airborne contaminants.   You can request a written guarantee from the equipment manager stating the dust collector meets the standards.  Size the collector properly for the application and area.  An undersized dust collector can result in high pressure drop, frequent filter changes, high energy usage, and a host of larger maintenance issues.

If you are being accountable for a  high standard of sustainability shouldn't you require your dust collector supplier to do the same.  You can request a sustainability report or other documentation as evidence of its green manufacturing initiatives.   The use of a VFD variable-frequency drive controls fan speed effectively and efficiently.

To read the full article and learn additional steps to consider for a truly sustainable dust collection system please visit Green Manufacturer Magazine.
You may also find more information regarding the EPA Standards here.

Industrial Dust And The Human Body

Sometimes we get caught up in the mechanics, regulations, and safety of why an industrial dust collection system is needed.  Other times we are concerned with combustible dust and it's dangers, but what about the effects of dust on the human body.

Whenever people inhale airborne dust at work, they are at risk of occupational disease. Year after year, both in developed and in developing countries, overexposure to dusts causes disease, temporary and permanent disabilities and deaths.  The World Health Organization offers documents to help educate and train people and employers in the prevention and control of dust in the workplace.

Irritant dust can settle in the nose and may lead to inflammation of the mucus membrane as well as inflammation of the trachea or the bronchi.  According to the Canadian Centre for Occupational Health and Safety "The lungs are constantly exposed to danger from the dusts we breathe."  The most dramatic dust reaction of the lung occurs in the deepest parts of the organ, leaving scarring and impaired normal lung function.  The amount of dust particles that settle in the lung also effect the capacity of the lung and the ability to take full deep breathes.   Many lung diseases are caused by inorganic dust exposure to silica, tin, tungsten carbide and coal.  Even organic dust such as hair particles, hay, and dust of heat treated sludge can cause disease to the lung.

The eyes are not immune to the effects of dust particles.  Even most safety glasses allow small dust particles to reach the eye causing irritation and/or possible damage to the cornea.   OSHA has certain standards in place to limit exposures to specific dust and fumes.  Inhalation of cobalt metal, dust and fumes may cause interstitial fibrosis, interstitial pneumonitis, myocardial and thyroid disorders, and sensitization of the respiratory tract and skin.   Some diseases of the heart have been linked to dust and fumes.

You can find out more about health and dust related issues through the following links.
World Health Organization
Canadian Centre for Occupational Health and Safety
OSHA

Article: Determining Total Cost of Ownership of Your Dust Collector Filters

Many of you may have an existing dust collector and have a need to replace or add an additional collector to a new process or application. A recent article in the 2011 Q4 issue of SprayTime, a quarterly magazine published by the International Thermal Spray Association (ITSA), addresses ways of determining your true cost of ownership. To most facilities a replacement filter is just a commodity and the cheapest priced filter is often purchased. So how much does that filter really cost you in the long run?

There are so many things to be considered when deciding on the true cost of a dust collector replacement filter. Emission thresholds, dust size and shape, energy, disposal, and even maintenance costs to name a few. This four page article is full information that can assist you in making informed decisions when it comes time to replace your dust collector filters.

You can visit the ITSA website, get a free subscription to the magazine, or download the PDF file of the complete issue and article from the highlighted links.

Video - Inferno: Dust Explosion at Imperial Sugar

This month is the four year anniversary of the deadly combustible dust explosion at Imperial Sugar Refinery in Georgia. We wanted to depart from our dust collection series this week to remember the 14 employees that were fatally burned. This explosion was preventable and sadly there have been many more deadly combustible dust explosions elsewhere since.

This video is part of a safety video series put out by the CSB (U.S. Chemical and Safety Board). The video report contains footage, animations, and interviews surrounding that investigation and details of how the explosions happened.

Article: What's The Best Type Of Dust Collector Filter For Applications Involving Sticky Dusts?

This week I would like to get away from combustible dust and address a different and unique application involving sticky dusts. This is not a common issue but it comes up from time to time and the solution can be hard to find. When moisture is combined with dust the outcome can produce many types of issues for a dust collector.

A recent article by John Dauber in Powder and Bulk Engineering PBE-News addresses testing, types of filter media, coatings, and external devices involved in the solution process.

You can read the full article here.

Article: Asking The Right Questions About Cartridge Dust Collection

Over the past decade, cartridge-style dust collectors have overtaken baghouses as the preferred technology for pharmaceutical dust collection. Combining maximum filtration efficiency with compact size and reduced pressure drop, a high efficiency cartridge dust collector will in most cases be the system of choice.

Choosing the best cartridge collection system for a given application, however, involves research and attention to detail. This article will review four key areas of investigation. By reviewing these topics with a knowledgeable equipment supplier and knowing the right questions to ask, engineers will be better equipped to make informed dust collection decisions. Read the full article here.

New Video Showcases Dust and Fume Collection Capabilities, Equipment

Camfil Farr Air Pollution Control (APC) has produced a video that describes how the company’s dust collection products and capabilities can help factories be safer, more productive and more energy-efficient.  The video can be viewed at http://www.youtube.com/watch?v=r3lPq7qY3TU. 

The 9-1/2 minute video includes an overview of Camfil Farr APC capabilities – including engineering services, application and technical support, and in-house dust testing at the company’s full-service dust test laboratory.  It also showcases the award-winning Gold Series® dust collectors and HemiPleat® filters, which are all produced through integrated manufacturing at company facilities. Applications and markets served worldwide are detailed in the video as well.

Dust Collectors and Sustainability

Are you green conscious? You don't have to compromise when faced with buying dust collection equipment for your factory. Ask about the environmental benefits of the dust collector you're considering. By definition, these systems are designed to stop thousands of different pollutants from entering the workspace air and the outside air. Well-built equipment that lasts will create less waste over time. Some high efficiency filters in the dust collector can last twice as long as others, which contributes to sustainability while saving energy. Even the paint used on a dust collector can be contribute to sustainability. The powder paint process is environmentally friendly, emitting no VOCs to atmosphere. Furthermore, premium efficiency fans provide optimum energy efficiency. For further information, download a PDF brochure on sustainability and dust collection here.

Dust & Fume Collection for Solar Panel Fabrication

For silicon wafer plants, fine fumes from the furnaces and laser cutting process must be extracted to protect workers and machines from the super fine dust that they emit. With the cadmium glass process, much more attention is needed due to the toxic nature of cadmium. Containment features such as Bag-In Bag-Out (BIBO) filter access and dust discharge removal are recommened. Also recommended are HEPA secondary filters to meet very stringent EPA laws which are at or below 0.0004 grains per cu ft (1 mg/cu meter). Click here to view dust collector installations at solar panel fabrication facilities and learn more.

Dust Collectors for Mining

Controlling dust from mining equipment at excavation sites, mill transfer points and similar locations is a difficult challenge. The EPA has strict limits on annual emission amounts. If emissions are too high, production schedules may be curtailed. That's why proper selection of dust collection equipment (including pleated baghouses) is such an important concern. Minimizing emissions allows production of more product.

Rock crushing, coal mining dust processing, and bin venting of quarry storage are mining applications. Some are really tough on dust collection equipment and call for custom components. Stack test results of less than .0005 grains per cubic foot of emissions can be achieved with the right configuration and filter media. One of the main concerns with pleated filter media is how well they hold up against moisture. Read more at Dust Collectors for Mining...

Case Study: Dust Collection in Plasma and Wire Spray Operations

Read about one company in Atlanta, GA that was experiencing problems collecting metal dusts from a plasma and wire spray operation that produces metal coatings for rolls used in the printing industry - and how switching to the right type of cartridge dust collector reduced downtime and disposal costs.

This type of application can be very challenging. Various types of wires made of 316 stainless steel, Monel® alloy, zinc, and other materials are fed into the spray gun two at a time. The wire spray gun is fed with a compressed air line. The compressed air blows through these wires as they cross, creating an arc that blasts the wire onto the roll to form the coating. The wire spray is very fine, mostly submicron particulate and is inconsistent in shape, causing a difficult challenge for the dust collector.

This published article can be very helpful if you have a similar application. Read the entire case study Dust Collection in Plasma and Wire Spray Operations.

Dust Collectors for Chemical Processing

Pesticides, paint pigments, agricultural dry chemicals - from ingestible powedered drugs to mouse poisions, each dust collection application will present specific concerns. Filter media is especially important for chemical processing.

This web page focuses on collecting dust in chemical processing applications. Linked is an informative article on chem.info entitled "How to Tackle Combustible Dust With Successful Dust Control Systems."

Collecting and Testing Dust

Testing dust is beneficial in many ways. By identifying the dust characteristics properly, you can determine the right type of collector (such as baghouse or cartridge system) and filtration media for your needs and determine the size equipment you need for optimial energy savings and operational efficiency. By using the right equipment, you can minimize maintenance problems and reduce emissioins while extending filter life.

The article Collecting and Testing Dust emphasizes the scientific approach to dust and fume collection by using dust sample testing as the basis for sound and accurate equipment selection. More often than not, equipment decisions are based solely on guesswork, on previous experience, or on general recommendation from suppliers. Finding the right dust collection system is a complex task affected by dozens of variables. The situation does not lend itself to guessing games.

This article, Collecting and Testing Dust, is also downloadable as a PDF file.

Dust Collectors for Blasting

Dust collection in blasting applications varies from the types of blasting such as wheel blasters, air blasters and cabinet blasters to the blasting media itself like sand, steel, plastic, slag and various shot.

There are special safety considerations for aluminum blasting and blasting with silica sand. When recirculating air, precautions should be taken to meet all OSHA and government guidelines...

Read more on Dust Collectors for Blasting.

New Explosion Venting Requirements

The article Five Ways New Explosion Venting Requirements For Dust Collectors Affect You tells you what you need to know about the new NFPA 68 standard on explosion venting for combustible dusts. This information can help you better understand what's changed in this revised standard and how it will affect your dust collection choices today and in the future.