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Dust Treatment Design Scheme of Shijiazhuang Xibu Manufacturing

Author：中环绿洲Date：2026-05-18 11:18:225

Information summary：

Entrusting Party: Shijiazhuang Xibu Machinery Co., Ltd.

Design Institution: Zhonghuan Lvzhou (Shandong) Equipment Manufacturing Co., Ltd.

1. Project Overview

During the automobile production process of Shijiazhuang Xibu Machinery Co., Ltd., a large amount of dust is generated in processes such as metal cutting in stamping workshop, injection molding polishing in synthetic resin workshop, engine mechanical processing and pretreatment in coating workshop. Such dust features complex components and scattered discharge points, which not only affects production accuracy and product quality, but also endangers employees’ occupational health and violates the enterprise’s green development goals. To consolidate the leading position of environmental protection benchmark, ensure production safety and staff health, the enterprise entrusts the design institute to customize a special dust treatment scheme with cartridge dust collector as the core equipment.

2. Pollutant Analysis and Hazards

2.1 Main Pollutants

The main pollutants of this project are multi-component industrial dust, which can be divided into three categories according to different production processes: 1. Metal dust (mainly steel and aluminum particles) generated by stamping and mechanical processing; 2. Plastic dust (such as PP and ABS resin particles) from synthetic resin workshop; 3. Paint-containing dust and mixed dust produced in coating pretreatment and polishing processes, mainly composed of metal oxides, resin residues and coating additives.

2.2 Formation and Hazards of Pollutants

This type of dust is mainly produced by high-speed contact between tools and workpieces or material friction and crushing during metal cutting, component polishing and resin processing. Its hazards are reflected in three aspects: human health, production safety and environmental quality.

2.2.1 Hazards to Human Health

Metal dust particles with particle size ≤5μm can penetrate deep into human lungs. Long-term inhalation may cause pneumoconiosis, metal poisoning and other occupational diseases. Organic components in plastic dust and paint-containing dust can irritate respiratory mucosa and skin and trigger allergic diseases. Some ingredients may affect nervous system functions through metabolism, posing continuous threats to front-line operators.

2.2.2 Production Safety and Quality Risks

Both metal dust and plastic dust belong to combustible dust. When accumulating to the explosion limit in closed workshop space, dust is extremely prone to explosion accidents in contact with electric sparks or high temperature. Meanwhile, floating dust easily adheres to auto parts, especially precision engine components and coating surfaces, resulting in reduced assembly accuracy and paint defects, increasing rework costs and weakening product market competitiveness.

2.2.3 Ecological Environmental Impacts

Uncollected dust drifts to the factory and surrounding areas, polluting the atmosphere and surface vegetation. Paint-containing dust may cause soil pollution with rainwater infiltration, which is inconsistent with the enterprise’s environmental development concept and damages its environmental demonstration image.

滤筒除尘

3. Design Basis and Principles

3.1 Design Basis

Environmental Protection Law of the People's Republic of China
Atmospheric Pollution Prevention and Control Law of the People's Republic of China
GB 16297-1996 Comprehensive Emission Standard of Air Pollutants
GBZ 2.1-2019 Occupational Exposure Limits for Hazardous Factors in Workplace Part 1: Chemical Hazardous Factors
GB 3095-2012 Ambient Air Quality Standards
Relevant technical specifications for air pollutant control engineering
GB 50243-2016 Code for Acceptance of Construction Quality of Ventilation and Air Conditioning Engineering
GB 50235-2010 Code for Construction and Acceptance of Industrial Pipeline Engineering
Electrical industry national standards: GB 50054-2011 Code for Design of Low Voltage Power Distribution
GB 50034-2013 Standard for Lighting Design of Buildings
GB 50055-2011 Code for Design of Power Distribution for General Electrical Equipment
Special technical specifications for dust control in automobile manufacturing industry
On-site survey data and production & environmental protection requirements of the enterprise
Mature cases and technical data of dust treatment in domestic and foreign automobile industry

3.2 Design Principles

Benchmark Compliance Principle: The emission concentration and rate of treated dust shall not only meet national mandatory standards, but also reach international advanced levels, conforming to the enterprise’s environmental positioning of national environmentally friendly project and ISO 14000 environmental management system.
Safety Adaptation Principle: In view of the characteristics of multi-component combustible dust, explosion-proof and anti-static design of equipment shall be strengthened, equipped with dust concentration monitoring and automatic alarm system to adapt to the high automation and continuous production rhythm of automobile manufacturing.
High-efficiency Precision Principle: Combined with the characteristics of multi-process and scattered dust generation points, the mode of "zoning capture and centralized treatment" is adopted. High-efficiency cartridge dust removal equipment is selected to realize precise treatment of different types of dust.
Economic Long-term Principle: Optimize equipment layout and pipeline design to reduce system energy consumption. Wear-resistant and anti-adhesive special filter materials are adopted to extend the service life of vulnerable parts and control operation and maintenance costs while ensuring treatment efficiency.

4. Design Objectives

Through the systematic treatment of the cartridge dust removal system, the following core objectives are achieved to consolidate the enterprise’s leading position in environmental protection:

The dust emission concentration strictly complies with GB 16297-1996 and local relevant standards, with external emission concentration ≤5mg/m³, which is better than conventional standards to highlight the enterprise’s environmental responsibility.
Exhaust funnels of each factory shall be set in accordance with specifications. The height of the main exhaust funnel of a single factory shall not be less than 25 meters to ensure sufficient high-altitude diffusion of purified waste gas and eliminate impacts on the surrounding environment.
The dust concentration at each operating point in the workshop is controlled below 4mg/m³ (complying with GBZ 2.1-2019), which thoroughly improves the operating environment, eliminates dust explosion hazards and protects employees' occupational health.
The overall system has a dust removal efficiency ≥99.5% and a high degree of automation. It can realize remote monitoring and intelligent operation and maintenance, meet the demand of three-shift continuous production and adapt to the intelligent manufacturing system.

5. Dust Treatment Process Design and Description

5.1 Process Selection Basis

The production dust of Shijiazhuang Xibu Machinery Co., Ltd. has prominent characteristics including complex components, fine particles, scattered dust generation points and slight viscosity of partial dust. The enterprise has extremely high requirements on the efficiency, stability and intelligence of the dust removal system. Therefore, the pulse jet cartridge dust removal process is selected for this scheme, which is maturely applied in the automobile manufacturing industry with the following core advantages:

Excellent filtration accuracy: PTFE membrane-coated filter cartridges are adopted, with a collection efficiency of 99.9% for metal dust and plastic dust above 0.3μm, which can effectively control fine dust emission and ensure the external discharge concentration far below the standard limit.
Compact structure: With large unit filtration area and small equipment volume, it is suitable for the dense workshop layout of automobile factories, saving installation space and plant renovation cost.
Efficient ash cleaning: The pulse jet ash cleaning has high strength and efficiency. The cleaning cycle and pressure can be accurately adjusted according to different dust types to prevent cartridge blockage, especially for slightly viscous coating dust.
High intelligence: The system can be linked with the enterprise’s existing production monitoring system to realize real-time dust concentration monitoring, equipment operation early warning and automatic start-stop control, adapting to the intelligent manufacturing demand of the automobile industry.

5.2 Process Flow Chart

Dust generation stations (stamping / polishing / resin processing / mechanical processing) → Zoned special gas collecting hood (negative pressure precise capture) → Anti-static ventilation pipeline → Pre-cyclone separator (coarse dust pretreatment) → Pulse jet cartridge dust collector → Induced draft fan → High-efficiency demister → Standard exhaust funnel → High-altitude discharge

Supporting System: Intelligent discharge valve → Classified closed ash storage bin → Dust recycling and compliant disposal device

5.3 Detailed Process Description

Zoned precise capture: Customized gas collection systems are designed according to the dust generation characteristics of different processes. Downward suction hoods are adopted for cutting stations in stamping workshop to fit the sedimentation characteristics of metal dust; enclosed hoods are equipped for resin polishing stations to prevent plastic dust diffusion; universal flexible suction arms are applied for engine processing stations to adapt to the processing of workpieces with various specifications. The hood mouth wind speed is designed at 1.5-2.0m/s to form a stable negative pressure area and realize source dust capture.
Safe conveying and pretreatment: 304 stainless steel anti-static ventilation pipelines are adopted, and conveying branches are divided according to factory areas to reduce pipeline crossing. Guide plates are installed inside the pipeline to reduce resistance, and grounding devices and dust concentration monitoring points are arranged every 5 meters. Dust-containing gas firstly enters the pre-cyclone separator to separate coarse dust particles (particle size ≥10μm) by centrifugal force, reducing the filtration load and extending the service life of filter cartridges.
Core filtration and purification: The pretreated dust-containing gas enters the filter chamber of the cartridge dust collector. Fine dust is intercepted by the membrane on the outer surface of the filter cartridge, and the purified gas passes through the filter cartridge into the clean air chamber. When the system resistance reaches the set value (1500Pa), the pulse control system is automatically activated to instantly jet high-pressure nitrogen to the filter cartridge, so that the dust layer falls off into the ash hopper to realize efficient cartridge regeneration without interrupting continuous system operation.
Classified dust disposal: Dust in the ash hopper is discharged into special closed ash storage bins through intelligent discharge valves (with weighing function) according to categories of metal, plastic and mixed dust. Recyclable pure metal dust is recycled by professional institutions, plastic dust can be processed into industrial fillers, and mixed dust is disposed of by qualified institutions to realize solid waste recycling and reduction.
Fine tail gas treatment and discharge: The purified gas is sent to the high-efficiency demister by the induced draft fan to remove trace oil mist and water vapor. Finally, the gas is discharged at a high altitude through an ultra-high exhaust funnel. Online monitoring equipment is installed on the top of the exhaust funnel to upload dust concentration data in real time for dual supervision by environmental protection departments and the enterprise.

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