DUST COLLECTORS

Typical Industries Served:

Petrochemical, Food/Agricultural, Wood Processing,
Chemical Pharmaceutical, Paint/Coatings

INTRODUCTION
Dust collection is the process of removing or collecting solid particles from airflow to
comply with stringent air pollution standards. Large filters trap airborne particles before
they are released into the outside air. Bag Type collectors are one of the most common
air pollution control technologies that removes particulate matter from the air waste
stream being emitted from a broad range of industrial processes. The particulate-laden
air stream passes through a woven or felted fabric that filters out the particulate matter
and allows the air to pass through.

A dust fire can be a devastating occurrence to an industrial facility. Damage to plant

facilities, lost production time, increased insurance premiums, and injury to plant
personnel are some of the costs associated with an incident of this type. There are
many different types of dust collection systems in the industry using various methods to
separate the dust from the air stream. Some Dust Collectors examples are:

Bag Type Collectors

Cyclone Collectors
Electrostatic Precipitators
Wet Collectors

The purpose of this application profile is to provide an understanding of the possible

hazards associated with dust collection systems and protection strategies utilizing
Buckeye Carbon Dioxide Extinguishing Systems. This document is intended to be a
guideline and is not applicable to all situations. Buckeye’s Carbon Dioxide Design,
Installation, and Maintenance Manual and NFPA 12 should be referred to when
designing systems. If you have any questions, please contact the Buckeye Fire
Equipment or our regional sales manager in your area.

THE PROBLEM: IGNITION OF BAG FILTERS

Dust fires are relatively common occurrences in a variety of industries. Plants equipped
with pneumatic handling and air filtration systems have an inherent risk associated with
the operation of these systems. Bag Type Collectors used for the collection of fine dusts
present a special problem because of the use of combustible fabric even where the dust
is noncombustible. Even bags of low combustibility will not withstand temperatures
normally encountered under fire conditions. Because of the combustibility of the bags,

Buckeye Fire Equipment

110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com
ductwork, or of the material being transferred through them, the installation of an
automatic carbon dioxide extinguishing system is justified.

Bags in collectors are considered combustible when cotton, wool, nylon, polypropylene,
or acrylic materials are used. Non-combustible bags consist of Nomex, Teflon, or
fiberglass materials. Carbon dioxide extinguishing systems are implemented when lower
temperature collectors are filtering combustible dusts and utilizing combustible bags.

Bag fires generate from normal manufacturing process sparks or embers being drawn
into the collector and attaching to the bags. Collector maintenance and repairs have also
lead to a fire condition.

Dust Collectors are also susceptible to explosions. Explosion Venting, Isolation and
Suppression are also protection strategies that can be implemented. A carbon dioxide
system will not prevent explosions in Dust Collector systems. NFPA 68 focuses on
Venting Systems and NFPA 69 on Explosion Suppression and Isolation Systems. These
standards should be referred to when employing explosion protection.

THE SOLUTION: TOTAL FLOOD – DEEP SEATED FIRE

Deep-Seated hazards are those in which the materials involved are subject to
smoldering fire conditions. The materials in Dust Collectors are subject to deep-seated
burning. Deep-Seated fires are best extinguished when a three-dimensional
extinguishing agent is utilized. Carbon dioxide agent will easily penetrate all parts of the
Collector and quickly extinguish fires to restore operation as soon as possible without
damaging internal components.

Automatic sprinkler protection will protect the Collector framework, but may not prevent
loss of the bags, which can be a costly replacement. Sprinkler systems do not provide
three-dimensional fire fighting characteristics, making them ineffective. Another
drawback associated with sprinkler systems is if the water discharge continues for an
extended period of time, damage to the Collector framework is likely due to excessive
weight from the water.

Dust Collector carbon dioxide systems are designed to provide a concentration of 75

percent by volume. Thirty-percent concentration is reached within the first two minutes
of the discharge. The designed percentage (75%) is achieved in less than seven
minutes. After the 75 percent concentration is achieved, it shall be maintained for a
substantial period of time, but not less than twenty minutes.

In accordance with NFPA 12, it is recommended to shutdown and or damper the

ventilation system prior to the carbon dioxide system discharge. When a ventilation
system cannot be shutdown prior to the carbon dioxide system discharge, additional
agent must be added to compensate for the volume leaving the enclosure. Special
design must also be applied when there is potential for over pressurization. If the dust
collector has an airtight enclosure, the internal pressure from the carbon dioxide
discharge could increase and require venting to prevent damage to the enclosure or
vent panel activation.
Buckeye Fire Equipment
110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com
Ductwork or other equipment that can lead to fire propagation should be assessed to
determine if fire protection is necessary. It is good fire protection practice to provide
protection in every potential hazard of Dust Collector units.

NOZZLE AND DETECTION REQUIREMENTS

The “S” Nozzle is best suited for a dust collector application. The “S” Nozzle design
provides a soft agent discharge and helps decreases the potential for turbulence. High
turbulence near each nozzle will stir up dust and could lead to an explosion. Installing
more nozzles will help minimize the overall flow rate and decrease the potential for an
explosion.

Rate-compensated heat detectors, installed in the ductwork and at the top of the
collector, are recommended to detect a fire and release the carbon dioxide system.
High-speed infrared detectors are also an adequate means of detection. Detectors are to
be installed between the process and the collector and be interlocked to actuate a
carbon dioxide system in the duct or in the collector. The detection system should also
shut down the rotary if one is present. This will prevent transferring burning material out
of the collector.

In addition to the detectors

releasing the carbon dioxide
system, a manual release
station should be conveniently
located to electrically activate
the discharge. Audible devices
are also installed to warn and
notify personnel of the carbon
dioxide discharge.

There are many different types

of Dust Collector designs
filtering various different kinds
of materials. The picture
example depicts a Bag Type
Dust Collector, which dislodges
dust from the bags by way of
reverse airflow.

Buckeye Fire Equipment

110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com
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This Design Guide provides a step by step design process of a Buckeye Carbon Dioxide
Extinguishing System protecting a Baghouse type Dust Collection System. There are
numerous unique Dust Collection systems filtering numerous different products. This
Design Guide is intended to be a sample and is not applicable to all Dust Collection
Systems. Buckeye’s Carbon Dioxide Design, Installation, and Maintenance Manual and
NFPA 12 should be referenced when designing systems.

This carbon dioxide design guide will be a deep seated fire hazard protecting a
Baghouse type Dust Collector with no leakage or ventilation compensation. The
following design parameters have been taken into consideration to determine the
amount of agent, flow rate, quantity of nozzles, and ultimately a Buckeye CO2 parts list.

Example:
1) Dust Collector with combustible filter bags
2) Ventilation system to shutdown upon discharge
3) All leakage areas sealed
4) Hazard Size: 14 ft. (4.3 m) long x 6 ft. (1.8 m) wide x 18 ft. (5.5 m) high

STEP #1 - DETERMINE THE HAZARD VOLUME

The first step is to calculate the total volume of the hazard being protected.

The volume is determined by multiplying: length x width x height.

Volume = 14 ft. x 6 ft. x 18 ft. = 1,512 ft3 (4.3 m x 1.8 m x 5.5 m = 42.6 m3)

STEP #2 – DETERMINE THE FLOODING FACTOR

The flooding factor used for a system design is based on the specific hazard being
protected. To determine the base quantity of Carbon Dioxide agent required, multiply
the hazard volume by a flooding factor selected from the following table:

Minimum Carbon Dioxide Concentration and Flooding Factor

Both the minimum Carbon Dioxide concentration and flooding factor are based on the
specific hazard being protected. For this example, a dust collector (bag house) requires:

• Minimum Carbon Dioxide concentration = 75%.

• Flooding factor = 0.166 lb. CO2/ft3 (2.66 kg CO2/m3)

Buckeye Fire Equipment

110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com
STEP #3 – CALCULATE THE MINIMUM EXTINGUISHMENT
QUANTITY REQUIRED
The minimum quantity of Carbon Dioxide required is based on the volume of the hazard
being protected and the Flooding Factor. Multiply the volume of the hazard times the
correct flooding factor.

STEP #4 – DTERMINE DISCHARGE DURATION AND FLOW

RATE
Deep-Seated hazard systems are discharged at a slower flow rate and for a longer
duration to counter-act the characteristics of a smoldering fire. For Deep-Seated fires,
the design concentration shall be achieved within seven (7) minutes, but at a flow
rate that will provide a concentration of 30% within two (2) minutes. To calculate the
minimum flow rate for a 30% concentration, multiply the hazard volume by 0.043
(0.688 for metric calculations). This will determine the amount of Carbon Dioxide to be
discharged within two (2) minutes. Dividing the resultant quantity of Carbon Dioxide
by two (2) provides the required flow rate in pounds (kg) of Carbon Dioxide per
minute. (Reference: NFPA 12, Section 2-5.2.3)

NOTE: For Deep-Seated hazards requiring a 75% concentration, the flow rate required
to discharge within seven (7) minutes is greater than the 30% requirement stated
above, and must be used.

STEP #5 – DETERMINE NOZZLE TYPE AND QUANTITY

For most applications, a surface-mounted nozzle arrangement that allows the discharge
piping to be run outside of the bag house is preferred. Therefore, the nozzle selected
should either be a flange-mount Vent or “S” Type nozzle. For applications where stirring
up dust may present an explosion hazard, the “S” Type nozzle would be preferred
because it will create a “softer” discharge application of the carbon dioxide within the
bag house.

A single nozzle of either type will deliver the flow rate required for this example, but
multiple nozzles should be provided to ensure complete coverage around the bag filters.
For this example, a minimum of two nozzles should be used.

Buckeye Fire Equipment

110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com
STEP #6 – DESIGN CONSIDERATIONS
Carbon Dioxide extinguishes fire primarily by displacing oxygen in the flame zone by
creating an inert atmosphere. Dust Collectors are subject to an enormous amount of air
movement. To allow the Carbon Dioxide system to achieve its primary extinguishing
mechanism of oxygen displacement, proper shutdown of fresh air supply and the loss of
carbon dioxide concentration should be implemented. Installing dampers in the “air
intake” and “air exhaust” as well as shutting down the fans shall be implemented.
Shutting down the fans should be done prior to the carbon dioxide discharge. Dampers
are activated pneumatically with pressure trip assemblies, which are part of the CO2
distribution piping. By implementing these design parameters, and isolating the
collection system, the fire is starved of oxygen.

If total air shutdown is not possible and dampers are installed, air pressure from the
fans will allow leakage through the ductwork, assuming the dampers will not be entirely
effective. Additional carbon dioxide gas will be required to compensate for a non-static
flooding condition. When this particular condition appears with your application, Buckeye
Fire Equipment should be consulted to provide assistance in designing the Carbon
Dioxide system.

STEP #7 – DEVELOP PARTS LIST AND PERFORM

CALCULATIONS
At this point you are now ready to develop your basic parts list from Buckeye Fire
Equipment’s CO2 Design Manual or Price List and perform the required flow calculation.
Using Buckeye’s CO2 flow calculation software, you can configure your system to meet
the actual conditions, size piping, determine nozzle orifices, and verify that the system
will deliver the proper flow rate for the required time frame. Lastly the flow calculation
program will give you a detailed parts list for ordering.

Buckeye Fire Equipment

In addition to Buckeye’s Carbon Dioxide System, Buckeye has an extensive product
offering for facility and process protection for commercial and industrial applications:

Fire Extinguishers – Buckeye offers a full line of fire extinguishers. Buckeye offers,
water, dry chemical, Carbon Dioxide and clean agent fire extinguishers. Buckeye’s clean
agent extinguisher utilizes Halotron and is offered in sizes up to a 2A 10BC rating.

Fire Detection Systems – Buckeye offers detection products from single hazard to
multi hazard systems. These controls are suited for fire alarm, agent suppression
systems, or sprinkler/pre-action fire detection and control systems.

Fire Suppression Systems – Buckeye offers a full range of suppression systems to

protect your equipment and/or process. Because Buckeye offers more than one choice
of extinguishing agents you are certain to get the right agent for your hazard. Buckeye
systems incorporate the following agents:

HFC-227ea
Carbon Dioxide
Foam
Buckeye Fire Equipment
110 Kings Road • Kings Mountain, NC 28086
Phone: 704-739-7415 • Fax 704-739-7418 • www.buckeyef.com