Not every industrial project starts with a “clean sheet.” In many cases, the greatest investment potential lies not in the purchase of new equipment, but in the conscious use of existing resources. Such a direction was taken at our client’s plant, where the reorganization of production – the extinction of one line and the dynamic development of another – necessitated the adaptation of the dust collection system to a new process configuration.
Instead of building a completely new plant, the decision was made to relocate and comprehensively upgrade the SBF filter, along with the expansion of pneumatic conveying and safety systems. The project covered both the mechanical and process parts, as well as electrical and fire protection.
Starting point – reallocation of power in response to a change in production structure
The plant underwent a significant change in the process load structure. In one part of the facility, the wooden detailing production line was extinguished, while in another part a decision was made to intensively develop a line for the production of furniture fronts. This shift in production capacity directly translated into a change in the capacity requirements and configuration of the dust collection system.
The front line generates dust and wood chips of explosion class St1. The dynamic growth of this area forced the expansion and adjustment of the dust collection system to accommodate larger and differently distributed loads.
Instead of investing in a new unit, it was decided to use the filter previously operating at the extinguished line. Thus, the key task became not only its physical relocation, but its full integration into the developed part of the plant and the adaptation of the operating parameters of the entire plant to the new process conditions.
Stage one – disassembly, diagnosis and refurbishment
The modernization began with the dismantling of the SBF filter and a detailed inspection of its technical condition. The condition of the filter baskets, material transport elements (sluices, strainers), as well as the supporting structure was verified. The unit was prepared for transport, cleaned of silicones and subjected to surface restoration.
The filter underwent a powder coating process, which was not just an aesthetic treatment. The restoration of protective coatings increases corrosion resistance and prolongs the life of the device, especially under conditions of intensive operation.
In parallel, the filter cleaning system was upgraded, which improved the efficiency of filter bag regeneration and stabilized the operating parameters under new loads.
An important part of the upgrade was the replacement of the fan with a JK-80MTD model with an assumed capacity of 50,000 m³/h. The selection of the device took into account not only the required flow rates, but also the characteristics of the duct system and the target pressure losses.
The fan was installed in a sound-absorbing cabin, which made it possible to reduce noise emissions into the environment. In practice, this means improving working conditions and meeting environmental requirements without the need for additional acoustic screens.
Integration with the new line
The relocation of the filter was only the beginning of the process. Its full integration into the new technological structure of the plant is crucial. This requires redesigning parts of the dust collection system, adjusting the flow system and ensuring proper cooperation with the existing ventilation infrastructure and control system.
The development of the production line also entails the need to expand the plant with additional collection points and adapt material handling to the new operating conditions. The modernization includes mechanical and drive components responsible for waste discharge, so as to ensure stable and continuous operation of the system under increased loads.
The entire system was designed in accordance with ATEX requirements, which in the case of wood dust of class St1 is of fundamental importance for process safety and operational reliability of the installation.
Pneumatic transport between halls – ensuring process continuity
The next stage of the project was to merge the two production areas into one cohesive material handling system. With the change in the plant’s operating logic, it became necessary to ensure the efficient and safe transfer of waste between the halls so that the entire system would function as an integrated whole.
The project included the design and construction of a new conveying line, taking into account optimal flow parameters and the durability of components working in contact with abrasive material. At the same time, structural solutions were adapted to the external conditions and the existing building infrastructure.
An important element of the work was also the adaptation of safety systems – including spark detection and extinguishing – to the new plant configuration. These changes were aimed at maintaining a high level of fire protection and ensuring stable system operation regardless of operating conditions.
Strengthening security systems
The change in the geometry of the installation and the expansion of transportation required an increase in the number of detection points in the fire protection system. The expansion of the safety system was an integral part of the project, not an addition carried out at the end of the investment. In dust collection plants, process safety must be designed in parallel with the mechanical and flow parts.
The end result – asset management engineering
The completed project confirms that upgrading an existing plant can be a full-fledged alternative to a new investment. The customer obtained a system adapted to the changed production structure, optimized investment costs and extended the life cycle of a key piece of equipment.
This type of implementation requires not only installation experience, but above all design competence: flow analysis, verification of pressure losses, assessment of explosion and fire risks, and control integration.
Modern industrial engineering is not just about providing new equipment. Increasingly, it means the conscious management of existing infrastructure, its relocation, optimization and adaptation to changing production realities.
