Dry Fog Systems
D.S.I. MODULAR SYSTEM DESIGN
A well designed dust suppression system must meet the following criteria in the harsh environment of material handling plants. Ease of Installation - If a system requires extensive plumbing and electrical work, the installation costs can sometimes exceed the capital cost of the equipment due to the need for specialized personnel. Low Maintenance - Because of the size of many material handling plants and the lack of maintenance personnel a good system can quickly deteriorate and lose efficiency if it requires extensive maintenance. Ruggedness - Material handling facilities are among the harshest environments for process equipment and if not properly designed and protected will quickly be rendered useless. Flexibility - Changes in plant flow and layout are not uncommon, especially in portable plants. If the various components of a dust suppression system are not universally designed, scrapping and repurchasing components can be costly. Freeze Protection - Since water is an integral ingredient in a dust suppression system, a low cost, easy to install freeze protection system should be incorporated into the design and not be added as an afterthought. In answer to these criteria, the following design standards have been incorporated into every D.S.I. system:
Ease of Installation - The various components necessary for a complete system include ultra-sonic fogging nozzles with universal mounting brackets, nozzle flow control components such as air and water regulators, solenoid valves, safety pressure switches, air and water filters, pressure gauges, manual/automatic selectors, status indicators, purge timers, thermostats, etc. Optional items include PLC's for automated control integrated into plant systems, automatically actuated self-cleaning filters, remote permissives for automatic system actuation, etc. These components have been packaged into "modules" which are easily mounted and connected together by flexible tubing conduit. Tubing connections are then made inside the modules by simply pushing the tubing into instant push-lock type connectors. Notools are required. Electrical control systems are Pre-Wired to our other control components simplifying installation. System control and power connections are made on pre-numbered terminal strips. The D.S.I. system can easily be installed by plant maintenance personnel if required.
Low Maintenance - The areas of a water based dust suppression system that are most susceptible to high maintenance are nozzle damage due to flying material, fouling of components due to scale and rust from piping and clogging of nozzles and valves due to improper filtration. The D.S.I. system has eliminated these problem areas with well thought out design and construction of our components. For example, as explained in the section PRINCIPLE OF OPERATION under Foggers, the inherent design features of the unique ultrasonic fogger make it a self-cleaning device. It does not become clogged from dissolved minerals in the water like hydraulic and air atomizers do. Secondly, the universal fogger mount is constructed out of corrosion proof materials that can stand up to the rigors of heavy material handling. Besides being rugged, it is designed to shield the fogging nozzle from flying material. The armored fogger can be slipped from its mount for inspection by hand without interrupting the operation of the system or material flow. All parts of the fogger and fogger mount are constructed of non-corrosive materials to eliminate corrosion from electrolysis.
To eliminate fouling of the system due to rust and scale, all interconnecting air and water tubing downstream from the filters is constructed of nylon tubing which eliminates scale and rust buildup characteristic of metal pipe. This tubing is encased in a flexible watertight PVC conduit which is terminated to each module by a universal slip-fit corrosion-proof watertight connector. This interconnection assembly can be impacted by heavy material and rebound to its original shape. Should the conduit and tubing be cut, the interconnection can be replaced in minutes by any non-skilled personnel without special tools. To eliminate rust and scale buildup from water standing in the lines, the system has been designed to automatically air purge all water from the lines at the end of each cycle. The cycle time is fully adjustable. To protect the system from undissolved solids in the water supply, the D.S.I. system incorporates single or dual-parallel cartridge type water filters often supplemented by a permanent media automatic backwash filter. With dual-parallel filters, the filters are supplied with individual isolation valves so that the spent filter can be taken "off-line" and changed while the stand-by filter can be put "on-line" for uninterrupted operation. Filter housings are supplied with an integral drain valve which is tubed outside of the module to maintain a dry interior during cartridge change. Construction of the cartridge filter housings is 100% stainless steel for long corrosion free operation. All other valves and components are constructed of brass or stainless steel.
Ruggedness - All modules are fabricated using industrial gauge NEMA rated enclosures specifically designed for indoor and outdoor use to protect the enclosed equipment against dust, washdown, rain, sleet and snow. Standard enclosures are constructed of heavy gauge steel with an industrial grade enamel finish. The door is mounted to the enclosure by means of a stainless steel hinge pin for superior corrosion />resistance. Stainless Steel and NEMA 9 Explosion Proof enclosures are options we provide for areas that require their use.
Flexibility - Because of the modular design, the system can easily be expanded by adding additional modules as the needs of your plant changes. Since each module is universal in design, the modules can be moved and reused. In the case of portable plants, the entire system can easily be moved by disconnecting the tubing conduits and reconnecting once the plant has been moved to its new location. Additional foggers can also be added to existing modules with the purchase of expansion kits.