Emerson’s proven products work together to deliver a complete intelligent dust collector automation solution with advanced diagnostics and floor-to-cloud connectivity.
Emerson announced the availability of a new Dust Collector Monitoring and Control system. A wide range of industries—including cement, mining and metals, chemicals and plastics, food and dairy, power, utilities, and others—handle products that emit considerable amounts of dust and particle matter.
Automating dust collection monitoring improves filtration, ensures environmental compliance, reduces maintenance costs, and prevents costly unplanned downtime.
This intelligent, simple-to-implement technology also works smoothly with existing plant automation systems, extending dust collector equipment life and improving overall operational efficiency.
Dust collectors are meant to capture potentially harmful airborne particles and odors, which is critical for protecting people and the environment, as well as guaranteeing equipment reliability and compliance with environmental regulations.
They vary in size and are designed to hold filters, which must be monitored for function, cleaned on a regular basis with compressed air, and replaced when they fail or reach the end of their useful life.
Intelligent monitoring and control can help to decrease maintenance expenses and total cost of ownership. Smart filter cleaning can help reduce energy expenses and compressed air consumption. Detecting and recognizing failing filters helps to avoid regulatory penalties.
Furthermore, prolonging filter life by as much as one year might result in savings of up to $18,000. Dust filters and pulsating solenoid valves are key components in many manufacturing and production activities, therefore avoiding downtime and compressed air leaks can save thousands of dollars each hour.
Emerson provides essential elements for high-performance dust collectors across multiple industries, including mechanical and automation products like 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’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.
Emerson’s dust collector monitoring and control system, which optimizes pulse valve use with advanced algorithms and predictive diagnostics, can improve valve and bag life, eliminate compressed air waste, and preserve dust collector equipment while avoiding costly repair and downtime.
Leadership Comments
“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.
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