Cutting of air ducts and shaped products. Aspiration is an air purification system in hazardous industries. Purpose and features of air ducts

The modern building is an enterprise, industrial facility, private house- it is impossible to imagine without an air exchange complex. Ventilation is a key component of any building engineering communication. Without timely supply, processing and removal of air flows, it is extremely difficult to maintain an optimal climate for technical personnel and conditions for correct operation. production equipment. cutting fittings industrial ventilation is an extremely important stage in the installation of an air exchange complex. A number of activities for the manufacture of components ventilation pipes requires exclusively vocational training and implementation.

Industrial air exchange system

Brief information about ventilation

The purpose of any air exchange is the uninterrupted supply and processing of air flows with their subsequent removal outside the premises. The natural method of ventilation is hardly suitable for an industrial facility.

Most often, ventilation is associated with filtration cleaning, as well as cooling/heating of the air mass.

Industrial ventilation is a forced process, which is possible only thanks to specialized climate equipment.

There are three types of forced ventilation:

  1. supply;
  2. exhaust;
  3. Combined (supply and exhaust ventilation).

Ventilation of an industrial facility

It is the combined air exchange scheme that is considered as the most best method organizing the movement of air in the room. The inlet part of such a complex is responsible for the access and processing of fresh air flows, and the exhaust component is responsible for their timely and effective removal from the specified area.

Organization of such complex system air exchange includes a number of important stages, each of which is a guarantee of the successful implementation of the project. One of these milestones is the design, during which the units and equipment that are most suitable for a given room are determined.

Sample project documentation

A modern industrial air exchange system is impossible without:

  1. air ducts;
  2. fans;
  3. Heaters (devices for air exchange);
  4. cooling devices;
  5. Supply complexes responsible for timely air access;
  6. Various filters to purify the air from harmful impurities and gases.

It was not in vain that we mentioned air ducts in the very first place. If the fan can be defined as the “heart” of any forced air exchange system, then the air ducts are the “arteries” through which air moves in a strictly specified direction.

Air pipes

Purpose and features of air ducts

A properly designed air duct network is the basis of an effective ventilation complex. That is why modern air exchange systems need a variety of shapes and characteristics of these products.

It may be mentioned that only metal pipes to move air there are more than 10 various kinds. These "arteries" must have high fire resistance, anti-corrosion, acid resistance, etc. Sheet metal (copper, aluminum, titanium alloys), plastic, fiber cement - all these are the materials from which air ducts are made. There are also round and rectangular sections of such pipes, each of which has its own individual characteristics. Let's also mention flexible, rigid, as well as semi-rigid air pipes. Etc.

Plastic air duct

In other words, the choice of air duct products depends on the wishes of the customer, the engineering features of the industrial premises, the purpose and installation of the air exchange network.

Manufacturing technology of air pipes

Production ventilation ducts and fittings (read - detail, element) must ensure highest quality joints and connections. This will allow leveling possible losses of air circulation in the future and more efficiently and without significant time costs to install the air exchange network. The accuracy of the production of pipe components depends on properly debugged automated control of instruments and machines.

Shaped elements of the ventilation system

The qualification of specialists is also extremely important; how rationally they will be able to markup, as well as cutting sheet material(we consider the most common material - mild steel) for "patterns" of shaped parts of air ducts. Workers must be knowledgeable various compounds elements and details of the network, the constructive functionality of automation, as well as the key requirements for both material and equipment, enshrined in SNiP.

Selection of material and methods of work

The practical implementation of nesting begins with the selection of the appropriate material. Saturation, cooling/heating factors, yoke stiffness, vibration characteristics, and a number of other operational nuances must be taken into account.

An example of the layout of shaped components

The most common processing method sheet metal for cutting the elements of the air duct network, oxy-fuel cutting is used. This way you can implement:

  1. Directly cutting steel;
  2. Cutting profile metal;
  3. Cutting various scarves, flanges, as well as other blanks.

The connection of shaped components to each other - welding - also has a number of features:

  1. Conventional (manual) welding method - butt joints, excluding metal allowances;
  2. The seam or spot method provides for electric welding automation and allows material allowances.

Seam welding technology

The shaped elements of the air exchange network should be cut using combined templates. In addition to welding, their connection to each other into a single complex is possible in the following ways:

  1. Bells;
  2. flanges;
  3. Crimp bandages.

All these methods of fastening pipe elements essentially differ little from each other, however, they have their own individual characteristics. For example, a socket connection considers a ring that, when heated, is put on the end of the duct, and after cooling, it is connected to the pipe by welding. The same procedure is carried out in relation to the air duct itself. After that, the rings are fastened together by welding.

Sample engineering design tables

In order to prevent clogging, fittings must be made with smooth turns, according to a standard template.

It should be taken into account the fact that not all elements of the air duct network are the same in terms of wear resistance. Open some of the parts that fall into such a "risk zone", you need to produce so that these components can be replaced in the future without endangering the entire complex.

The most time-consuming and responsible operation is the marking of tees, transitions, crosses, etc. The cutting of such ventilation segments (up to 900 mm) must be performed according to the inventory combined templates. Parts whose diameter is more than 900 mm should be manufactured based on special engineering tables that provide markings by coordinates.

Production of air ducts

Production processes are often accompanied by the release of dust-like elements or gases that pollute the indoor air. The problem will be solved by aspiration systems designed and installed in accordance with regulatory requirements.

Let's figure out how they work and where they use such devices, what types of air purifying complexes are. Let's designate the main working units, describe the design standards and the rules for installing aspiration systems.

Air pollution is an inevitable part of many manufacturing processes. In order to comply with the established sanitary norms air purity, use aspiration processes. With their help, dust, dirt, fibers and other similar impurities can be effectively removed.

Aspiration is suction, which is carried out by creating an area of ​​low pressure in the immediate vicinity of the source of pollution.

To create such systems, serious specialized knowledge and skills are required. practical experience. Although the operation of aspiration devices is closely related to the functioning, not every ventilation specialist will be able to design and install this type of equipment.

For achievement maximum efficiency combine ventilation and aspiration methods. Ventilation system in industrial premises must be equipped to ensure a constant supply fresh air outside.

Aspiration is widely used in the following industries:

  • crushing production;
  • wood processing;
  • manufacturing of consumer products;
  • other processes that are accompanied by the release a large number substances harmful for inhalation.

Ensure employee safety standard means protection is far from always possible, and aspiration may be the only way to establish a safe manufacturing process in the workshop.

Aspiration units are designed to efficiently and quickly remove various small contaminants from the air that are formed during industrial production.

Removal of contaminants using systems of this type is carried out through special air ducts, which have a large angle of inclination. This position prevents the appearance of so-called stagnation zones.

Mobile ventilation and aspiration units are easy to install and operate, they are perfect for small businesses or even for a home workshop

An indicator of the effectiveness of such a system is the degree of non-knocking out, i.e. the ratio of the amount of contaminants that have been removed to the mass harmful substances not included in the system.

There are two types of aspiration systems:

  • modular systems– stationary device;
  • monoblocks– mobile installations.

In addition, aspiration systems are classified according to the level of pressure:

  • low-pressure- less than 7.5 kPa;
  • medium pressure- 7.5-30 kPa;
  • high-pressure- over 30 kPa.

The complete set of aspiration system of modular and monoblock type differs.

In hot shops, heating of the air coming from outside is not needed, it is enough to make an opening in the wall and close it with a damper.

Conclusions and useful video on the topic

Here is an overview of the unpacking and installation of the RIKON DC3000 mobile suction system for the woodworking industry:

This video demonstrates stationary system aspiration used in the manufacture of furniture:

Suction systems – modern and reliable way purification of air in industrial premises from hazardous contaminants. If the structure is properly designed and assembled without errors, it will demonstrate high efficiency at minimal cost.

Have something to add, or have questions about the topic of aspiration systems? Please leave comments on the post. The contact form is in the bottom block.

Now there is no such large industrial enterprise in nature, which creates a large concentration of:

  • raw materials;
  • energy capacities;
  • transport and GPM
  • workers;
  • other inventory items where deep air purification would not be needed.

This is an ordinary and undeniable requirement of the time itself regarding the preservation of the environment, life and health of people, increasing labor efficiency in the creation of goods and wealth to meet the needs of society.

A modern aspiration system in the working premises of factories, factories, chemical, oil refineries and other enterprises is the next step towards the development of ventilation to create a healthy workshop atmosphere, which, together with dust and gaseous production waste, was simply removed not so long ago directly into the ecological system of the region .

The process of aspiration differs from ordinary ventilation of rooms primarily in that the removal of dry suspension of the smallest particulate matter together with polluted air is carried out directly from working area, where the most intensive formation of environmentally harmful dust actually occurs. This approach to deep air purification technology is not only the most efficient, but also the most economical.

Equipment for aspiration plants

For each specific workshop, both the ventilation system that creates and controls air flows in the room, and the aspiration installations that are engaged in the direct removal of the smallest solid particles before they enter the air space shop or into the atmosphere, are developed jointly.

Deep air aspiration units are of two types:

  1. Monoblock when created completely offline installation with a closed process of selection, collection and disposal of dry dust particles. Therefore, it usually consists of one or more fans, filters and a special container for the concentration of the selected waste.
  2. Modular when designed one system with air ducts connected to different workplaces, fans of low and high pressure, separators, containers for collection and storage of waste. Such systems can be created both for a separate workshop and for the whole complex of production facilities of the plant.

There are direct-flow aspiration units, when the air flow after cleaning is released into the atmosphere, recirculation, when the clean air flow returns to the room either directly or through the ventilation system.

The main equipment of aspiration plants include:

  • Cyclones. This is a two-chamber ventilation device, creating a centrifugal air rarefaction high degree: large particles are concentrated in the outer chamber, and small particles accumulate on the surface of the inner chamber.
  • Filtration sleeves and pipelines. When passing through them, the polluted air flow loses a significant part of the solid inclusions on their walls.
  • Filters and settlers. They can be installed both instead of atmospheric cyclones and on pipelines at transitions to ventilation.
  • Catchers for large particles and metal chips. They are installed directly near the workplace, for example, next to machines.
  • Press and waste containers.

Evaluation of the work of aspiration in the workshop

Evaluation of aspiration performance on industrial production give:

  • by the total amount of disposed waste;
  • in relation to "non-disposal of harmfulness" to the "initial harmfulness" of the technological process. That is, in the air volume that has passed through the deep cleaning system, the amount of dust that has escaped disposal is determined.

The effectiveness of ventilation is determined only by the volume of air flow that was removed from the room without creating drafts that could be harmful to the health of workers.

Basically, the performance of the aspiration system is reduced by all kinds of leaks in the connections in the piping system and filtration sleeves. They create up to 15 - 20% loss of aspiration efficiency and make it necessary to install more powerful electric motors on cyclone fans. Therefore, it is necessary to periodically carry out inspections and scheduled preventive repairs on operating systems to eliminate defects at the joints of pipelines and filtration sleeves.

Design and installation of aspiration on working technological equipment

Increasing environmental requirements is a global trend of modern technological progress. Therefore, the installation of aspiration for almost all industrial enterprises is a mandatory technical measure that improves the culture of production.

For the design and installation of air aspiration equipment, it is not necessary to change existing technological processes. Since treatment plants are made to order, the design organization adapts the aspiration to the available technological equipment. Binding to the conditions of a particular workshop and accuracy in the calculations predetermine both the compressed terms of the installation of systems and the efficiency of its operation in the future.

At the design stage, in addition to the location of workshop equipment, sources of pollution and aspiration points, the following initial data are determined:

  • Air consumption and rarefaction reduction at each cleaning point.
  • The speed of movement of air flows through pipelines and sleeves of a certain diameter and length.

After that, calculations are made to establish the types of dust collectors, the diameters of the air ducts in each section are specified, the amount of waste and filters is determined, and so on.

After the creation of technical documentation, a plan is drawn up for carrying out installation work, achieving the minimum terms of stops of the technological process, which will be required for the direct installation of aspiration equipment.

Aspiration is designed to remove small dry particles from under the shelters of transport and technological equipment and the working area using the method of sucking them with an air stream (air is used as a carrier medium) into the pipeline of the aspiration system, through which particles with an air stream reach their destination (filter, sump and collected in any container). To eliminate dust emissions, aspiration systems with an extensive network of air ducts and gas cleaning equipment are used.

Installation and adjustment of aspiration plants is carried out at enterprises for the storage and processing of grain products, brick factories, quarries, etc.

Aspiration is different from ventilation the fact that in ventilation the work of the system is focused on controlling the flow of air as such, and in aspiration air is used only as a carrier, and the work of the system is focused on removing small dry particles.

Systems Design

The purpose of the aspiration system is to prevent the spread of harmful emissions from the source into the air of the working area. An aspiration device, as a rule, is required at woodworking, crushing and other enterprises of light and heavy industry, the technological process of which occurs with the release of harmful substances. The main difference of this type of ventilation from others is the large angle of inclination of the air ducts to prevent the formation of stagnant zones and high speed air flow.

The effectiveness of the system is evaluated by the so-called degree of non-knocking out, that is, the ratio of remote hazards to hazards that have avoided utilization by the local suction system and therefore got into the air of the working area.

There are two types of aspiration systems - monoblock and modular.

Monoblock suction systems

The advantages of monoblock systems include mobility and autonomy. Monoblock allows to place the unit close to sources of harmful emissions and provides easy connection to highways central systems aspiration. The monoblock unit consists of a fan, a separator (filter) and a waste tank, and can be mobile or stationary.

Modular suction systems

This type of system is more efficient modular system aspiration is designed and mounted based on the specific task set by the customer, the solution of which is full compatibility characteristics of the created device with technological process that required it.

The main elements and nodes of this system:

  • air ducts
  • cutting modules
  • presses, press containers

Aspiration systems have found their application in such industries as:

  • production of powders and bulk materials
  • processing and production of paper and cardboard products

Loss of performance

A significant share of productivity is reduced due to the presence of leaks in the system, creating losses of 5-10% [ ] . This phenomenon is often not considered when conducting an examination of already operating aspiration systems, or creating a project. The selection of the fan unit is made without taking into account the normalized losses, without recalculating the fan power with the required margin.

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