PROJECT REPORT PHARMACEUTICAL DUST EXTRACTOR(PDE)
Presented By: (Students Name) PRATIK PANCHAL KETAN PANCHAL
(Semester) th 8 th 8
(Permanent Roll No.) 06ME26 06ME25
Guided By: Prof. DHAVAL. M. PATEL PATEL DEPARTMENT OF MECHANICAL ENGG. U. V. PATEL COLLEGE OF ENGINEERING, GANPAT UNIVERSITY, GANPAT VIDYANAGAR, KHERVA-382 711, DIST. MEHSANA
1
CERTIFICATE THIS TO CERTIFY THAT SHRI: PANCHAL KETAN B ROLL NO. 06 ME 25 OF 8TH MECHANICAL CLASS HAS SATISFACTORILY COMPLETED THE PROJECT ON PHARMACEUTICAL
DUST
EXTRACTOR
WITHIN
WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.
SIGN :
DATE:
2
FOUR
CERTIFICATE THIS TO CERTIFY THAT SHRI: PANCHAL PRATIK H ROLL NO. 06 ME 26 OF 8TH MECHANICAL CLASS HAS SATISFACTORILY COMPLETED THE PROJECT ON PHARMACEUTICAL
DUST
EXTRACTOR
WITHIN
WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.
SIGN:
DATE :
3
FOUR
ABSTRACT The trend among pharmaceutical companies to develop selective drugs of high potency has pushed the industry to consider the potential of each hazardous ingredient to become airborne.Dustiness issues are not unique to the pharmaceutical industry, but are relevant to any industry where powdered materials are mixed, transferred and handled. Interest in dustiness is also driven by concerns for worker health, the potential for plant explosions and the prevention of product loss. Unlike other industries, the pharmaceutical industry is limited by the milligram quantity of powdered material available for testing during product development. These needs have led to the development of a bench-top dustiness tester that requires only 10 mg of powder and fully contains the generated aerosol. The powder is dispersed within a 5.7 liter glass chamber that contains a respirable mass sampler and a closed-face sampler to quantify the respirable and total dust that are generated with a given energy input. The tester distinguished differences in dustiness levels of five different powders. Finer powders were dustier, and the respirable dust percentage was always less than that for total dust. Four testers have been built and evaluated using pharmaceutical grade lactose. Dustiness measurements determined using all four testers were comparable. The pharmaceutical industry uses surrogates such as lactose to represent active compounds in tests that estimate the dust concentration likely to occur in i n a new manufacturing operation. Differences between the dustiness du stiness of the active compound and its surrogate challenge the relevance of the surrogate tests to represent true exposures in the workplace. The tester can determine the dustiness of both the active compound and its surrogate, and the resultant ratio can help to interpret dust concentrations from surrogate tests. Further, dustiness information may allow the pharmaceutical researcher to select powder formulations that present low airborne concentrations in the workplace
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INDEX SR NO.
CONTENTS
PAGE NO.
Abstract
iv
List Of Figure
vii
List Of Table
viii
Executive Summery
9
Introduction
10
Concept Of Dust Collector
10
2
Objectives Of Dust collection
11
3
Working Principle
11
4
Scope Of Project
11
5
Salient Features
12
6
Types Of PDE
13
7
Main Parts Of PDE
15
8
16
8.1
Function Of Main Parts Of PDE Intake Manifold
16
8.2
Dust Collecting Hopper
16
8.3
Rotor & Motor
16
8.4
Blower
17
8.5
Filtration Bag
17
8.6
Stapper
17
8.7
Caster wheel
17
10
Technical specification
18
1 1.1
5
11
Design Description
19
11.1
Rotor Specification
19
Calculation
25
12.1
Suction Capacity
26
12.2
Filtration Area
26
12.3
Dust Storage Capacity
26
13
Choice Of Dust Collector
27
14
Application
28
15
Advantages
29
16
Limits
29
17
Conclusion
29
18
References
30
12
6
LIST OF FIGURE SR NO.
NAME OF FIGURE
PAGE NO
6.1
Vertical Blower PDE
12
6.2
Horizontal Blower PDE
13
7.1
Overview of PDE
14
8.1
Intake Manifold
15
8.4
Filtration Bag
16
11.1
Rotor
19
11.2
Filtration Plate
20
11.3
Storage Drawer
21
11.4
Blower
22
11.5
Body Of PDE
23
7
LIST OF TABLE SR NO
NAME OF TABLE
PAGE NO.
2.1
Objectives of Dust Collector
11
9.1
Recommended Spares for 300 CFM Dust Collector
18
9.2
Recommended Spares for 150 CFM Dust Collector
18
13.1
Factors affecting on choice of Dust Collector
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8
EXECUTIVE SUMMERY Dust extraction system is used for many industries like as: Asphalt industry
The dust-bearing exhaust gases are fed into the dust collector at a temperature of 100 – 170°. The separation of coarser particles is carried out in a pre-separator (separation > 90mµ) and a skimmer (separation > 63mµ). The exhaust gases enter the filter’s crude gas chamber from above via the crude gas hood and then flow through the filter bags into the clean gas chamber. The achieved residual dust content lies well below the prescribed limiting value. The separated dust (sand and fine fillers) is fed back into the mixing process by discharge elements and screw conveyors. A main radial fan blows the purified gases out into the atmosphere via a chimney stack. Cement industry Cement manufacturing, handling,storage and distribution involve processes that require dust control.
Quarry and minerals industry Dantherm has long experience in providing centralised dust extraction installarions and individual units for mineral handling and processing, from aggregates to clay preparation for brick and ceramics manufacture. Tough reverse jet and reverse air fil ter units, with generous pre-separation sections and hard grade ducting can handle heavy abrasive dust loads efficiently and with minimal maintenance requirements. Crushing, screeniing, conveying, storage and outloadi ng may be handled by a single centralised dust extraction plant if required.
Pharmaceutical industry Pharmaceutical Pharmaceutical dust extractor machine is extremely useful in controlling the dust generated during the compression of tablets. These equipments are used to remove excess powder from compressed tablets. These Dust Extractor Machine is not only ensure a dust free end product for use but also health and safety of people coming in contact with pharmaceutical processing machines. Extracting hazardous dust at the point of origination and conveying them to the correctly designed filtration system is necessary to protect both personnel as well as the plant. These Dust Extractor Machine successfully capture dust with the air stream and convey it to the dust collector.
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1. Introduction
Pharmaceutical dust extractor is a machine collecting dust(powder) which is explosed by tablet press machine. Dust extractor
vary
widely
in design, operation, ef f fe ctiveness, space
requirements, construction, and capital, operating, and maintenance costs. Each type has advantages and disadvantages. Dust collection technology is taken lightly by the production or maintenance engineers of a manufacturing plant and they try to fabricate a simplistic collector, which, unfortunately, never works. It is not uncommon for us to deal with such customers who have either tried their own hands or have taken the services of a back-yard fabricator for this purpose and have burnt their fingers. A poorly designed/manufactured dust collector might cost less to begin with, but it might cost a lot over a short/medium term and may achieve absolutely nothing. Manufacturer, supplier and exporter of Pharma Machines including dust extractor machine for collecting loose powder or dust from the polishing chamber.
Our dust
extractor unit is used to control the flying dust that is automatically generated during the compression of tablets. It is also used for various stages of cleaning operations when coupled with tabletting machine and automatic capsule filling machine. Controlling dust hazards and cross contamination at tablet compression, reducing mechanical strain and balanced air blowing system are some of the ideal features of our dust extraction machine. 1.1 Concept of dust Collector In simple words - A suction hood is placed near the source point. This suction hood is connected to the dust collector which sucks in air and the dust comes along with it. This dust is separated from the carrier air and the clean air is allowed to escape , either within the premises or
outside.
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2. Objectives of Dust Collection
There can be several objectives of collecting dust, some of the important reasons can be following: Protection of the operator Protection of the production equipment from the dust Protection of the job from the effects of dust Protection of quality of environment in a premises Recovery of the expensive materials Table2.1-Objectives Table2.1-Objectives of Dust Collection
3. Working Principle
Pharmaceutical dust extractor machine is extremely useful in controlling the dust generated during the compression of tablets. These equipments are used to remove excess powder from compressed tablets. These Dust Extractor Machine is not only ensure a dust free end product for use but also health and safety of people coming in contact with pharmaceutical processing machines. Extracting hazardous dust at the point of origination and conveying them to the correctly designed filtration system is necessary to protect both personnel as well as the plant. These Dust Extractor Machine successfully capture dust with the air stream and convey it to the dust collector. 4. Scope of Project
• Design and fabrication of PDE. • Selection & Implementation of major components – Motor, Rotor, Blower, etc • Integration of all other engineering details
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5. Salient Features •
Dust Extractor Machine is provided with stainless steel 304/ 316 contact parts
•
In this Dust Extractor Machine, Blower fan is dynamically balanced and the unit is with castor wheels.
•
Overcome dust hazards as well as cross contamination at tablet compression.
•
Minimizes mechanical strain, excessive wear of tableting machine-resulting in minimum machine break-downs and punch wears.
• •
All inlet manifolds and dust collection tray are of S.S. Four inlet manifolds facilitate to connect Tablet Machine and the De-dusting units.
•
Machine in fitted with the castor wheels for easy mobility.
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6. Types of PDE
Fig 6.1- Vertical Blower PDE
13
Fig 6.2-Horizontal Blower PDE
14
7. Main Parts of PDE
Manif old
Dust collecting hopper
Filtration bag
Rotor & Motor
Blower
Stapper
Caster Wheel
Fig 7.1-Overview of PDE
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8. Function of main parts of PDE 8.1 Intake manifold
Fig 8.1-Intke Manifold
Intake manifold is the main part of the PDE. Normally in the PDE there are four no. of manifold are used. For that two big flexible pipes are used. One end of the both pipes is attached to the both of the intake manifold and the other end is attached to the tablet press where we have to suck the dust powder. 8.2 Dust collecting hopper
Dust collecting hopper is used to collect the dust which is sucking by the blower also collect the small dust which is stappered by stapper through the filtration bag.Dust storage capacity of the Dust collecting Hopper is about 0.0040 m3. 8.3 Rotor & Motor
Roter is heart part of pharmaceutical dust extractor, by rotating rotor at high speed the air is sucked,the roter is provided with 12 number number of
blade each having angle of 20
degree.the inner & outer diameter of roter are 120mm &210mm respectively .moter is used having power of 0.5hp & 2800rpm. 8.4 Blower
Blower is used for the suction purpose. The main main function of the blower is to suck the dust powder from the tablet press through the intake manifold. Blower is designed according to required suction capacity.For this project the suction capacity of the blower is 240 CFM(cubic feet per minute) or 7.178 m3/m.
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8.5 Filtration Bag
Fig 8.4-Filtration Bag
Filtration bag is used to filter the big dust particle of the powder. Some of the small Dust particle is stick with the filtration bag and there after with the help of stapper all the particle which is sticked to the filtration bag is collecting at the dost collecting hopper. 8.6 Stapper
Stapper is used to collect the remaining small particle of the dust powder. Stapper is shake off the all small dust particle which is sticked on the filtration bag and collect it to the dust collecting hopper. 8.7 Castor Wheel
Castor Wheel is provided at the bottom of the machine to make the machine movable.with help of caster wheel machine is easly trantsport by dragging,without lifting machine.
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9. General Specification
RECOMMENDED SPARES FOR 300 CFM DUST EXTRACTOR MODEL 300 CFM STD/GMP SR NO PART NO MS MB NAME NAME OF THE THE PART PART
REQ. QTY
1
*
B
POLYPROPYLENE BAG
4
B
TENSION SPRING
4
3
B
U" RIBBON - 1/4" 3MTR
1
4
B
3/8" THREAD BACKLITE KNOBS
6
B
ELE.OVER LOAD RELAY 2.5 TO 4
1
2
X-9/7
5
*
Table-9.1 * Minimum Spares to be kept in stock
RECOMMENDED SPARES FOR 150 CFM DUST EXTRACTOR MODEL 150 CFM STD/GMP SR NO PART NO MS MB NAME NAME OF THE THE PART PART 1
B POLYPROPYLENE BAG
4
B TENSION SPRING
4
3
B U" RIBBON - 1/4" 2MTR
1
4
B 1/4" THREAD BACKLITE KNOBS
6
B ELE.OVER LOAD RELAY 2.5 TO 4
1
2
5
*
REQ. QTY
X-9/7
*
Table-9.2 * Minimum Spares to be kept in stock
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10. Technical Specification
Suction Capacity ( 430.69 m3 / hr.)
Filtration Area (0.4396 (0.4396 m2)
Dust Storage Capacity (0.0043 m3)
Inlet Connection 1 Nos. of Dia (38.1mm)
Power 0.5 HP / / 2800 RPM / / 3 Phase / / 440 V / / 50 Hz
Overall Dimensions 315 (L) X 315 (W) X 450 (H) (in mm)
11. Design Description 11.1 Rotor Specif ication
Inlet Diameter(D1)=120 mm
Outlet Diameter (D2)=200 mm
Speed of Rotor(N)=2800 rpm
Velocity of vanes=u1(m / s)
Velocity of a f air=V(m / s)
Vane angle(θ )=20 degree
Width of vane(B)=50 mm
19
Fig 11.1-Rotor
20
Fig 11.2-Filtration Plate
21
Fig 11.3-Storage Drawer(Dust Collecting Hopper)
22
Fig 11.4-Blower
23
Fig 11.5-Body of the PDE
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12. Calculation 12.1 Suction Capacity(Q)
Velocity of vanes(u1)
=
π D1N
60
=π ∗ 0.120 ∗ 2800 60
u1 =17.58 m/s Now θ
=20
Velocity of air(V) = u1tan θ V =17.58tan θ =17.58*tan20 V=6.39 m/s Now
Q = π ∗ v ∗ D1∗ B
=3.14*6.39*0.120*0.05 =430.69 m3/hr =7.178 m3/m Q=240 CFM 12.2 Filtration Area Dia of F f Filter Hole=100 mm Length of Filter bag=350 mm n=No. of h f hole Filtration Area=
π
Dl∗ n
=3.14*0.100*0.350*4 =0.4396 m2 12.3 Dust Storage Capacity
Cs=Length(l)*Width(w)*Height(h) =285mm*275mm =4310625 mm3
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13. Choice of a Dust Collector
Dust collectors vary widely in design, operation, effectiveness, space requirements, construction, and capital, operating, and maintenance costs. Each type has advantages and disadvantages. However, the selection of a dust collector should be based on the following general factors: Dust concentration and particle size - For minerals processing operations, the dust concentration can range from 0.1 to 5.0 grains (0.32 g) of dust per cubic feet of air (0.23 to 11.44 grams per standard cubic meter), and the particle size can vary from 0.5 to 100 µ m.
Degree of dust collection required - The degree of dust collection required depends on its potential as a health hazard or public nuisance, the plant location, the allowable emission rate, the nature of the dust, its salvage value, and so forth. The selection of a collector should be based on the efficiency required and should consider the need for highefficiency, high-cost equipment, such as electrostatic precipitators; high-efficiency, moderate-cost equipment, such as baghouses or wet scrubbers; or lower cost, primary units, such as dry centrifugal collectors. Characteristics of airstream - The characteristics of the airstream can have a significant impact on collector selection. For example, cotton fabric filters cannot be used where air temperatures exceed 180° F (82°C). Also, condensation of steam or water vapor can blind bags. Various chemicals can attach fabric or metal and cause corrosion in wet scrubbers. Characteristics of dust - Moderate to heavy concentrations of many dusts (such as dust from silica sand or metal ores) can be abrasive to dry centrifugal collectors. Hygroscopic material can blind bag collectors. Sticky material can adhere to collector elements and plug passages. Some particle sizes and shapes may rule out certain types of fabric collectors. The combustible nature of many fine materials rules out the use of electrostatic precipitators. Methods of disposal - Methods of dust removal and disposal vary with the material, plant process, volume, and type of collector used. Collectors can unload continuously or in batches. Dry materials can create secondary dust problems during unloading and disposal that do not occur with wet collectors. Disposal of wet slurry or sludge can be an
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additional material-handling problem; sewer or water pollution problems can result if wastewater is not treated properly. The choice of the dust du st collector has to be made on the basis of following factors:
a. The process or the activity from where the dust is being generated b. The type of material being process, e.g. steel, graphite, plastic, rubber, etc. c. Nature of the dust being generated - its particle size population, temperature, shape of the particles, and other properties; like whether it is hygroscopic, toxic, inflammable, free-flowing or sticky, etc. d. Quantum of dust : The peak quantity of dust generated per minute e. Location of the dust collector with respect to the production equipment f. Whether a suction hood is already installed, and, if not, what are the parameters which are going to affect the design of the suction hood, like size of the source point, no. of source points, other working/moving components in the vicinity of the job, loading/unloading of the job, etc. g. What kind of dust disposal system will meet the requirements of the system - whether a batch disposal or continuous disposal will be required. Table-13.1
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14. Application:• •
To Remove powder f rom tableting machine.
• •
To remove stick ed powder f rom tablet in de-dust machine.
• •
To remove powder f rom multi-mill machine.
• •
At the out put of the granulator.
• •
Similar concept is also utilized in Asphalt industry
• •
This concept is used even in Quarry and minerals industry,cement industy.
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15. Advantages •
Modular design provides optimum field flexibility and short manufacturing lead time - have it your way fast
•
Heavy duty carbon steel construction for long life.
•
Due to the filtration bag small Dust also can be collect
•
Available in standard unitary type models & custom based specially designed models for PDE
•
All the units are designed & manufactured as per GEP & GMP
•
Available in Single skin/Double skin & MS/SS construction.
16. Limits •
Can’t be use in heavy Duty application.
•
Noise produced due to the rotor & motor.
17. Conclusion
It is the responsibility of the system designer to ensure that there are adequate air flows and velocities in the system and that the selection of duct components and fan equipment has been optimized
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18. References Web Reference • •
www.wik ipedia.org
• •
www.danthermfiltration.co.uk
• •
www.camfilfarrapc.com
• •
www.farrapc.com
• •
www.milkeninstitute.org
• •
www.techf low.net
• •
www.cm1981.in
• •
www.cadmech.in
• •
www.f luidpack .in
• •
www.nfsrps.com
• •
www.cimaindustries.com
• •
www.bapihvac.com Books Reference
• •
Fluid mechanics and Hydraulic Machines by R K Bansal.
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