Effective RCS Control from Dust Control Environmental

The Stockton Casting Co Envirojet Bag Filter pst install

Stockton Castings Envirojet Installation

Sector: Foundry
Process Area: Sand Reclamation
Control of: Respirable Crystalline Silica (RCS)
Dust Type: Oleophobic & Hydroscopic
Dust Collector: Envirojet Reverse Jet Bag Filter

Introduction

Growing from a small foundry to an expansive global operation, Stockton Castings, based in Stockton-on-Tees, make high integrity complex castings, catering for a wide range of industry sectors.

Stockton Castings manufacture casts in a spectrum of ferrous alloys and typical weights being between one and 1500 kilos with sand casting being part of the process. Supporting the company’s environmental and sustainability goals, a sand reclamation system is used to recover and reuse foundry sand after casting. The process can generate harmful respirable crystalline silica (RCS) that if uncontrolled, poses serious health risks.

Stockton Castings invested in upgrading their LEV and environmental controls in 2023, installing a bespoke dust collection system designed and supplied by industry specialists Dust Control Environmental, resulting in the elevated control of process RCS.

Below details how Dust Control Environmental met requirements and the benefits Stockton Castings experience from an enhanced dust extraction system.

Project Requirements

Efficient extraction from 3 points – Shake Out Deck, Ladder Sand Feed and Cooler Classifier.
Filter capable to handle and separate particulates from chemically bonded foundry sand.
Limited installation space.
Easy particulate separation and collection for disposal or reuse.
A durable filter body that could withstand environmental elements of the foundry processes.

How DCE met the Requirements

Dust Control Environmental surveyed and understood the Stockton Site requirements recommending the implementation of their Envirojet, reverse jet bag filter extraction system.

The Envirojet was installed externally with clip together ducting from the designated extraction points out to the filter inlets. Designed for a 18/20 m/sec conveying velocity to mitigate fall out of material and all installed to HSG 258 guidance and best practice. Paramount for safety, the ducting incorporates an inline spark arrestor.

The DCE Envirojet filter unit benefits from a 3mm thick steel plate modular construction supported by galvanised rolled steel section legs. It houses 90 unique oval bags with DCE Oleophobic dust release media for efficient reclamation. The fan is floor mounted.

Waste collection and removal will be facilitated via a single pyramid waste collection hopper with a rotary valve for auto discharge into bulk waste bags.

As the structure will be operating in a harsh environment, to ensure structure longevity, the Envirojet body is finished in a powder coating primer and textured topcoat resulting in protection of approximately 120 microns.

The installation, commissioning and training was carried out by Dust Control Environmental. They will also offer aftermarket support to Stockton Castings with LEV testing, parts and maintenance service work.

The Benefits

Now the Envirojet dust control system has been installed in their sand reclamation plat Stockton Castings will reap the following benefits:

Enhanced HSE & environmental compliance.
Higher protection for workforce against RCS.
Sand reclamation and reuse capabilities made easier with single point waste collection.
Oval bags result in compact footprint and reduced height of filter.
Inline spark Arrestor provides high safety functioning.
Reverse jet cleaning system requires no shutdown offering a true 24/7 operation.
Durable filter body finish and construction ensure longevity and aesthetics.

N.B. Images show the near new condition, minimal body wear and tear, from installation to 3 years later.

First Name & Last Name	Email Address	Telephone Number	Postal Address
Job Title	Company Name	IP Address	Cookie Identifier

Website Address	Email Addresses	Telephone Numbers
Billing Address	Delivery Address

Number of Users	Unique Visitors	Session Duration	Pages Visited	Bounce Rate
Traffic Sources	Demographic Information	Device & Browser Information	Conversion Rates	Click-through Rate (CTR)

Type of Information	Examples	Time Period	Disposal of Information
Personal information A combination of digital and hard copies.	First Name & Last Name, Email Address, Telephone Number, Postal Address, Job Title & Company, Name, IP Address, Cookie Identifier	72 months if customer transactional 24 months if marketing & no engagement	Archiving & deleting digital data & shredding of hard copies.
Company Information A combination of digital and hard copies.	Website Address, Email Addresses, Telephone Numbers, Billing Address, Delivery Address	60 months if customer transactional 24 months if marketing & no engagement	Archiving & deleting digital data & shredding of hard copies.
Customer Financial Information A combination of digital and hard copies.	Payment Information, Customer Orders	72 months if customer transactional	Archiving & deleting digital data & shredding of hard copies.
Employee Data A combination of digital and hard copies.	Employee ID, Competence & Training, Bank Details	72 months	Archiving & deleting digital data & shredding of hard copies.
Website User Stats A combination of digital and hard copies.	Number of Users, Unique Visitors, Session Duration, Pages Visited, Bounce Rate, Traffic Sources, Demographic Info, Device & Browser Info, Conversion Rates, Click-through Rate (CTR)	24 months	Archiving & deleting digital data & shredding of hard copies.