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Tag Archives: powertech pollution controls

Categories Mistkiller Author poweradmin 0 Comments

Application of FumeKiller® as an Oil Mist Collector

At site, 8no.s of CNC machines in a row had to be provided with suitable mist collectors. All CNC machines generated mist / fumes from neat cutting oil which had to be captured and the pollutants in the fumes are to be filtered effectively. 

Our FumeKiller®, electrostatic filters are well-suited to capture and control fumes generated during machining processes in CNC machines. These fume extractors can be used for the control of oil mist (neat cutting oil) as well as coolant mist (water-based coolant). Lower suction capacity fume extractors (FumeKiller®) can be installed for individual CNC machines. In case of multiple CNC machines larger capacity fume extractors can be installed along with suitable ducting to capture and route the generated fumes from the CNC machines to the oil mist collector (FumeKiller®). For neat cutting oil fumes, we always recommend Dual-pass electrostatic filters to provide high-efficiency filtration of fumes / mist. For water-based coolant fumes / mist single -pass filtration extractors work satisfactorily.

The installation was carried out using our FumeKiller® model FK6000/5hp mounted on a low MS angle stand with a large oil collector tank below the stand. MS ducting was mounted above the row of CNC machines with droppers to connect individual CNC machines. Last- mile connections were provided using PVC flexible hose. Even though our standard FumeKiller® model FK6000/5hp uses a 3HP motor to drive the suction fan, in this case we used a 5HP driven suction fan to provide higher static pressure because of the length of ducting involved.  

It was found that for a 2-shift operation, the filters within the oil mist collector filtered the pollutants for 4 weeks before getting choked. The cleaning cycle for the filters was established at 4 weeks. Just before getting fully choked, the filter module as well as the prefilters and postfilters are removed and cleaned using pressure water pump at about 110bar pressure. The filters are dried using a compressed air jet and repositioned inside the fume extractor. Adequate training was given to the maintenance technicians to handle the equipment. All safety features were explained and demonstrated. The equipment was found to be working satisfactorily.

Visit us: https://www.powertechindia.com

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Categories Fumekiller, Welding fume extractor Author poweradmin 0 Comments

Control of Component Welding Fumes – Fumekiller® model FK3600EM as a Welding Fume Extractor

The special purpose machine has two adjacent component welding stations. The welding fume generation area is open, without any enclosure. The welding process takes place only at one station at a time. The jobs are loaded manually by a skilled operator. During welding fumes are generated which are to be captured and the pollutants in the fumes are to be filtered effectively.  

Our Fumekiller®, electrostatic filter model FK3600/3hp was suggested to be mounted on an MS Grouted pipe stand of about 5ft height positioned just behind the welding machine. Two MS painted suction hoods were placed just above the two welding stations at a convenient height after studying operational comfort as well as optimum fume suction distance. The suction hoods were connected to a common MS ducting fitted to the Fumekiller® equipment and supported from the fume extractor.

The fume extractor was switched on during the welding process. The welding fumes generated at the two component welding stations were captured by the fume extractor through the 2nos of suction hoods placed above the welding spots effectively. The fume extractor should be operational as long as the welding process is being carried out.

The welding fumes consisting of various pollutants such as manganese, chromium, nickel, and other potentially harmful elements, enter the electrostatic filter (Fumekiller®) through the air stream. The ionisation section of the filter charges all particles 0.01 micron and larger in the air stream. The air enters the collection section where the pollutants adhere to the collection plates. Pollutants as small as 0.01 micron and larger are collected. The clean air is let out at the exhaust port of the fume extractor.

It was found that for a single shift, the filters collected the pollutants for about 3 weeks before getting choked. The cleaning cycle for the filters was established at 3 weeks. Just before getting fully choked, the filter module as well as the prefilters and postfilters are removed and cleaned using pressure water pump at about 110bar pressure. The filters are dried using a compressed air jet and repositioned inside the fume extractor. Adequate training was given to the maintenance technicians to handle the equipment. All safety features were explained and demonstrated.

Visit us: https://www.powertechindia.com

Categories Mistkiller Author poweradmin 0 Comments

MistKiller™ – Your one stop solution for mist control from water-based coolant

Ever wondered what harm a water-based coolant does to the people on your shopfloor?

A lot of people believe that using a water-based coolant is less harmful than using oil-based coolants.

On the contrary, even water-based coolants use soluble oils to ensure the longevity of the tool life (corrosion resistance, high friction resistance etc.). One characteristic of the commonly used water-based coolant is that they provide an ideal medium for microbial growth with consequent biological contaminants.

Knowing the risk of releasing contaminants into your immediate environment, would you still consider releasing the water-based coolant mist on the shop floor or the immediate outside environment?

Now that you’re aware of the harm it causes, we hope that’s surely not the case!

Introducing to you Powertech’s MistKiller™ unit – Your one stop solution for mist generated from water-based coolants.

Using the simple technique of centrifugal force, this mist collector unit incorporates a pre filter and post filter to ensure efficient filtration of the water-based coolant mist before releasing it into air. The air released is about 80%-90% clean which means there is a substantial reduction of pollutant in the mist.

The centrifugal force inside the unit, condenses the mist to liquid which can be routed back to your machine for re-use by means of a drain pipe.

Pre-filters in the form of Aluminum Mesh and Post Filters in the form of Foam Mesh provide excellent filtration and also are washable and re-usable.

What you get with our MistKiller™ is – 1 unit, 3 major benefits:

  1. Filtration of mist at the mist generation source.
  2. Coolant retrieval for re-use
  3. No replaceable cost of filters as these can be just washed and re-used

Are you in need of a mist collector to capture and control water-based coolant mist from CNC machining operations? Get in Touch with us today and we will work with you to provide the best possible solution for your specific requirements.

Categories Fumekiller, Welding fume extractor Author poweradmin 0 Comments

Successful Application of FumeKiller® as a Welding Fume Extractor

Introduction:

The FumeKiller® on multiple occasions was able to prove its worth with the effective capture and control of fumes generated from industrial processes. One of the most common processes which has employed the FumeKiller® is in welding. In this post, we look into a project where the FumeKiller® was successfully implemented as a welding fume extractor.

The Challenge: Control of Welding Fumes generated during manufacture and assembly of commercial vehicles.

The customer was an established company in the automotive sector and was faced with a very tricky problem – During the welding process conducted on commercial vehicles like trucks, fumes were generated from multiple points. The fumes were being generated from different points based on where the welding was being done and it was impractical and expensive to create a large extraction hood / station that would be capable of effectively capturing the generated fumes. The customer therefore needed a novel and custom designed solution to ensure successful extraction of the generated welding fumes.

The Solution: Single FumeKiller® model FK3600VEM equipped with Flexible Extractor Arm.

Due to the tricky nature of the problem, our team had to approach the issue with a creative mindset to ensure a viable solution for the same. After careful investigation and study of the workspace(s), we decided that the best solution to the issue would be to use a portable welding fume extractor equipped with a Flexible Extractor Arm and based on our study of the process, it was decided that the FumeKiller® model FK3600VEM would be used for the extraction of welding fumes. Some of the benefits of this solution include:

  • Portable FumeKiller® Unit: The FumeKiller® model FK3600VEM is a vertically oriented variation of the standard model. The unit itself is mounted on wheels and can be moved to different location depending on where the welding process is taking place.
  • Flexible Extractor Arm: Although not a part of our standard line of products, the Flexible Extractor Arm is one that is used specifically in situation like what the client was facing. The arm along with the portable fume extractor, allowed for adjustment of the extraction hood close to the welding point. This therefore, would ensure effective and efficient extraction of the generated welding fumesdirectly from the source, without spreading to the rest of the shopfloor.

Results and Impact:

The implementation of the FumeKiller® was a success which allowed for multiple benefits to our client:

Improvement in Air Quality: Since the fumes that were generated from the process were being extracted directly from the source, the remainder of the shopfloor remained pollution free. The direct result of this was a safer and healthier work environment for the staff.

Operational Efficiency: The FumeKiller® model FK3600VEM is a single portable fume extractor unit that allowed for a mobile extraction system that could be deployed to any location, as and when required. This negated the requirement of a bulky and expensive fume extraction station which may not have provided the same efficiency of extraction. The solution was therefore not only efficient but allowed the customer to benefit from significant cost savings as well.

Regulatory Compliance: The successful implementation of the FumeKiller® as a welding fume extractor resulted in the customer meeting the required air quality standards within the shopfloor.

Conclusion:

The success of the project is a clear example of how we use a unique approach to every single client and provide custom built solution for each requirement. We are committed to providing every customer with the most effective, efficient, and economical solution for their air pollution control needs. With our portable fume extraction system, we were able to address the welding fume issues faced by our customer and help to enhance the air quality and thereby worker safety within the shopfloor. The transformative impact of the FumeKiller® in this project clearly demonstrated its potential to create cleaner and safer workspaces. If you are facing a challenging issue to do with air pollution control, get in touch with us today and we will work with you to find the best possible solution.

Visit us: https://www.powertechindia.com

Categories Fumekiller, Soldering fume extractor Author poweradmin 0 Comments

FumeKiller® used as a Centralized Soldering Fume Extractor

Introduction:

With this project, we took an enormous stride forward in air pollution control by demonstrating the extraordinary capabilities of the FumeKiller®, our advanced soldering fume extractor. In order to address a major air quality issue, we worked closely with a client who encountered soldering fume issues at many workstations. This blog delves into the project’s complexities, describing the problem and the brilliant solution we supplied using the FumeKiller® technology.

The Challenge: Control of Fumes generated from multiple Soldering Workstations

Our customer, an established electronics manufacturer, was dealing with a serious problem: the unregulated release of soldering smoke in their production area. Soldering, a critical component of their operations, was posing health concerns to their employees and violating air quality standards due to generation of hazardous fumes. With several workstations continuously engaged in soldering processes at the same time, the customer required a complete system that could efficiently capture and control the soldering fumes.

The Solution: Centralized Fume Extraction System using FumeKiller® model FK3600EM.

Recognizing the severity of the situation, our team set out on an assignment to develop a comprehensive solution. After multiple consultations and careful investigation, we came up with the solution of deploying a centralized fume extraction system using FumeKiller® model FK3600EM as the final answer to their air pollution control needs.

  • Customized System Design: We painstakingly examined the client’s workspace layout to determine the best location for the FumeKiller® unit. This strategic arrangement enabled optimum coverage and effective extraction of soldering fumes from all workstations.
  • Powerful Extraction Technology: The FumeKiller® system boasts cutting-edge electrostatic filtration technology, which enables it to function as an effective and efficient soldering fume extractor. This feature dramatically decreases the release of pollutants into the ambient air, improvigng workplace safety and air quality.
  • Single Centralized Control: We optimized the client’s fume extraction infrastructure by supplying a single FumeKiller® machine to serve all workstations. This centralization simplified maintenance while also lowering operational costs, resulting in a cost-effective and efficient solution.
  • Customizable Features: The FumeKiller®‘s flexible design enables us to produce a specific model, in this case the FK3600EM, to meet the demand. It also allowed us to customize the extraction settings to the specific needs of each workstation. This adjustment ensured that the system was compatible with the client’s varied soldering processes.

Results and Impact:

The successful implementation of FumeKiller® yielded outstanding results for our client:

Improved Air Quality: The client noticed a significant improvement in air quality throughout their production area thanks to the robust extraction capabilities of our soldering fume extractor. Harmful soldering vapours were properly caught and filtered, resulting in a safer and healthier working environment for its staff.

Regulatory Compliance: Our solution enabled the customer to comply with stringent air quality rules, avoiding potential legal issues.

Operational Efficiency: The centralized extraction system improved the client’s workflow by eliminating the need for multiple exhaust systems. This improved productivity and resource usage.

Cost Savings: Our customer realized significant cost savings as a direct result of the unified strategy using the FumeKiller®, both in terms of equipment investment and ongoing maintenance.

Conclusion:

The successful execution of this project demonstrates our commitment to innovative and effective air pollution management technologies. By addressing our client’s soldering fume issues with a centralized extraction system, we enhanced not just their air quality and worker safety, but also their operational efficiency and environmental responsibility. The outstanding success of the FumeKiller® in this endeavour demonstrates its ability to alter industries, one clean breath at a time. If you are ready to take your air pollution management efforts to the next level, contact us today to learn about the transforming power of our fume extractors.

Visit us: https://www.powertechindia.com

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