Mist collectors are essential pieces of equipment used in various industries to ensure clean and safe working environments. They are designed to capture and remove mist, smoke, and other fine particles generated by industrial processes. Properly sizing a mist collector is crucial to ensure that it effectively captures and removes contaminants from the air.
In this blog, we will discuss the importance of sizing the right mist collector and provide a list of factors to consider when sizing your mist collector solution. We will also highlight common mistakes made when sizing mist collectors and provide tips on how to avoid them.
By the end of this article, you will have a better understanding of the factors to consider when sizing a mist collector and be equipped to make an informed decision when selecting the right one for your facility.
Table of Contents
What is a Mist Collector?
Mist collectors play a crucial role in maintaining a clean and safe working environment in various industries. During industrial processes such as cutting, grinding, and machining, fine particles including mist and smoke can be generated, posing serious health risks to workers and negatively affecting equipment performance.
Mist collectors are designed to capture and eliminate these harmful particles from the air by utilizing different filtration mechanisms. The type of mist collector used depends on the specific application and the properties of the mist being generated.
The benefits of using mist collectors include improved air quality, reduced health risks for workers, and increased equipment performance and lifespan. Additionally, many industries must comply with regulations and standards for air quality, and the use of mist collectors helps ensure compliance with these regulations.
Factors to Consider When Sizing a Mist Collector
Several factors must be considered when sizing a mist collector to ensure that it effectively captures and removes mist particles from the air. The type of mist generated by the industrial process, airflow rate, capture velocity, efficiency, and location are all essential factors to consider when selecting the right mist collector for your facility.
Type of Mist
The type of mist generated by the industrial process is a crucial factor to consider when sizing a mist collector. The size, shape, and density of the mist particles will determine the type of mist collector needed to effectively capture and remove the mist from the air.
Oil lubricant is a type of fluid used to reduce friction between moving parts in machinery, while synthetic coolant is a fluid used to cool down a manufacturing process, such as metalworking. Mist generation can occur when these fluids are used in industrial processes, and mist collectors can be used to capture and remove the mist from the air.
The type of mist generated by the use of oil lubricants and synthetic coolants can vary depending on the specific fluid and manufacturing process. Generally, mist generated by synthetic coolants is finer and more difficult to capture than mist generated by oil lubricants. Therefore, mist collectors used for synthetic coolant mist may require higher efficiency and additional features such as HEPA filters.
Airflow Rate
Determining the appropriate airflow rate is a vital consideration when sizing a mist collector. This rate is determined by the volume of air that requires cleaning within a given time. The size of the mist collector needed to effectively capture and eliminate mist particles is directly proportional to the airflow rate; higher airflow rates require larger mist collectors.
Machining techniques that have small enclosures, such as micro-machining or small parts machining, can produce very fine dust particles and mist that require a higher airflow rate to be captured and removed from the air. The small size of the enclosure can also limit the space available for air to circulate, making it more difficult for a mist collector or air filtration system to capture the airborne contaminants effectively. In these cases, specialized mist collectors or air filtration systems may be needed to compensate for the limited space available for air circulation.
On the other hand, larger machine enclosures used for manufacturing larger parts can require a lower airflow rate since there is more space for air to circulate and the larger parts produced may generate less fine dust particles or mist. However, the type of machining technique used within the enclosure can still have a significant impact on the required airflow rate.
Capture Velocity
Capture velocity is the minimum air velocity required to capture and contain the mist particles before they can escape into the surrounding environment. The capture velocity required depends on the size, density of the mist particles, and how much coolant is being used. If the capture velocity is too low, mist particles may escape and contaminate the surrounding environment.
Efficiency
Efficiency is an essential aspect to take into account when sizing a mist collector. It pertains to the mist collector’s capacity to capture and eliminate mist particles from the air. The effectiveness of a mist collector is influenced by several factors such as the type of mist collector, airflow rate, and the design of the ductwork.
Location
The placement of the mist collector can significantly affect its performance and efficiency in capturing and removing mist particles from the air. The distance between the mist source and the collector, the presence of obstacles between them, and the surrounding airflow patterns must all be taken into account when selecting and sizing the mist collector for optimal performance.
Luckily, Aeroex’s Technologies offers amounting kit, which provides flexibility in installation and allows the system to be configured to fit a variety of shop layouts and configurations.
Common Mistakes When Sizing Mist Collectors:
Several common mistakes can occur when sizing a mist collector. Oversizing or undersizing, failing to consider future expansion, and not considering the efficiency of the mist collector are all potential pitfalls that should be avoided to ensure the selection of an effective and efficient mist collector.
Oversizing or Undersizing
One of the most common mistakes when sizing a mist collector is oversizing or under sizing. Oversizing a mist collector can result in higher installation and maintenance costs, while undersizing can lead to inefficient mist collection and potential safety hazards.
Not Considering Future Expansion
Failing to consider future expansion is another common mistake when sizing a mist collector. It is essential to plan for future growth when selecting a mist collector, as failing to do so can result in the need for a larger mist collector down the line, resulting in higher costs.
Not Considering Efficiency
Not taking into account the mist collector’s efficiency is a common mistake that must be avoided. The effectiveness of a mist collector plays a crucial role in its ability to efficiently capture and remove mist particles from the air. A mist collector with low efficiency can lead to the dispersion of harmful particles into the surrounding environment, making it crucial to ensure that the selected mist collector is highly efficient.
Final Thoughts
Sizing the right mist collector is crucial to ensure a safe and clean working environment in various industries. Considerations such as the type of mist generated, airflow rate, capture velocity, efficiency, and location must all be taken into account when selecting and sizing the mist collector for optimal performance.
Common mistakes such as oversizing or undersizing, failing to consider future expansion, and not considering the mist collector’s efficiency should be avoided. By selecting the right mist collector and avoiding these common mistakes, industries can ensure compliance with regulations, reduce health risks to workers, and increase equipment performance and lifespan.
Size Your Next Mist Collector Perfectly with Aeroex Technologies
Need help sizing your next mist collector? Aeroex Technologies is a reputable and experienced manufacturer of mist collectors, with over 20 years of experience in the field. We provide a wide range of mist collectors that are designed to meet the specific needs of various industries, and our knowledgeable team can help customers select the right mist collector for their application.
Aeroex Technologies is committed to ensuring customer satisfaction, providing exceptional customer service, and delivering high-quality products. Our mist collectors are designed to effectively capture and eliminate mist particles from the air, improving air quality, reducing health risks for workers, and increasing equipment performance and lifespan.
Aeroex Technologies offers installation, maintenance, and support services to ensure that our customers’ mist collectors are properly installed and maintained for optimal performance. Our team of experts is available to answer any questions or concerns and provide guidance on selecting the appropriate mist collector size, airflow rate, capture velocity, and efficiency to meet their customers’ specific needs.
Choosing Aeroex Technologies as a partner for sizing mist collectors means customers can be confident that they are receiving high-quality, reliable, and effective equipment and support to ensure a clean and safe working environment. Get in touch to learn more about how we can help today.
