New dust collector monitoring and control solution enhances performance and environmental protection

Emerson has introduced a new Dust Collector Monitoring and Control solution, combining a range of its proven products to offer an intelligent automation system with advanced diagnostics and Floor-to-Cloud connectivity. This solution is designed for industries such as cement, mining, chemicals, food and dairy, power, utilities, and others that deal with materials that generate dust and particulate emissions. Automating dust collection monitoring is an efficient way to optimise filtration, ensure environmental compliance, minimise costly maintenance, and prevent unplanned downtime.

The solution integrates easily with existing plant automation systems, enhancing the lifespan of dust collector equipment and improving overall operational efficiency. Dust collectors play a critical role in capturing harmful airborne particles and fumes, protecting both people and the environment, while also ensuring the smooth operation of equipment and compliance with environmental regulations. These systems house filters that require performance monitoring, periodic cleaning with compressed air, and eventual replacement when they become ineffective.

Intelligent monitoring and control systems can significantly reduce maintenance costs and the total cost of ownership. Smart filter cleaning can help minimise energy consumption and compressed air usage. The ability to detect and identify failed filters also prevents costly regulatory penalties. Moreover, extending filter life by up to one year can result in savings of as much as $18,000. Since dust filters and pulsating solenoid valves are vital to manufacturing and production processes, preventing downtime and air leaks can save businesses thousands of dollars each hour.

Recognising the needs of various industries, Emerson offers a comprehensive portfolio of products that are essential for high-performance dust collectors. This includes mechanical and automation components such as ASCO™ pulse valves, pilot boxes, air tanks, pressure and particle concentration sensors, basic sequencer controllers, AVENTICS™ air flow sensors, Movicon™ HMI/SCADA visualisation interfaces, and PACSystems™ PLC, I/O, and edge analytics.

Samuele Oliva, product marketing manager for dust collectors and alternative energy within Emerson’s discrete automation business, stated: “With this world-class and easily implemented solution, we aim to help our users achieve greater operational efficiencies. The solution provides valuable insights that reduce reactive maintenance, lower the risk of downtime, minimise energy consumption, and extend equipment life. It also bridges the knowledge gap by making information more accessible to operations personnel.”

Emerson’s Dust Collector Monitoring and Control solution combines several key features that enhance its performance. It optimises the control of pulse valves and includes automated cleaning cycles for multiple filter lines. The Movicon.NExT SCADA system enables remote monitoring, alerts, reporting, and integration with existing systems. Additionally, the PACSystems PLC and AVENTICS solenoids feature built-in algorithms for efficient filter cleaning. The QuickPanel+ HMI provides real-time diagnostics and early fault detection, while scalability is offered based on pulse valve count (up to 500). The ASCO P152 particle concentration sensors can detect low dust levels and filter issues, and differential pressure monitoring is provided by Rosemount™ pressure sensors with optional 4-20 mA compatibility. The solution also includes monitoring capabilities for compressed air, pressure, temperature, dust levels, energy consumption, and predictive maintenance features.

By optimising pulse valve usage with advanced algorithms and predictive diagnostics, Emerson’s solution helps extend the life of valves and filters, reduce compressed air waste, and protect dust collector equipment, all while preventing costly maintenance and downtime.