1

PROJECT REPORT

PHARMACEUTICAL DUST EXTRACTOR(PDE)

Presented By:

(Students Name) (Semester) (Permanent Roll No.) PRATIK PANCHAL 8th 06ME26 KETAN PANCHAL 8th 06ME25

Guided By: Prof. DHAVAL. M. PATEL

DEPARTMENT OF MECHANICAL ENGG.

U. V. PATEL COLLEGE OF ENGINEERING, GANPAT UNIVERSITY,

GANPAT VIDYANAGAR, KHERVA-382 711, DIST. MEHSANA

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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 FOUR

WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.

SIGN : DATE:

3

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 FOUR

WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.

SIGN: DATE :

4

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 a new manufacturing operation. Differences between the dustiness 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

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1 Introduction

10

1.1 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 Function Of Main Parts Of PDE

16

8.1 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

6

11 Design Description

19

11.1 Rotor Specification

19

12 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

7

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

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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 27

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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 filter 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 outloading may

be handled by a single centralised dust extraction plant if required.

Pharmaceutical industry 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

PPhhaarrmmaacceeuuttiiccaall dduusstt eexxttrraaccttoorr iiss aa mmaacchhiinnee ccoolllleeccttiinngg dduusstt((ppoowwddeerr)) wwhhiicchh iiss

eexxpplloosseedd bbyy ttaabblleett pprreessss mmaacchhiinnee..

DDuusstt eexxttrraaccttoorr vvaarryy wwiiddeellyy iinn ddeessiiggnn,, ooppeerraattiioonn,, eeffffeeccttiivveenneessss,, ssppaaccee

rreeqquuiirreemmeennttss,, ccoonnssttrruuccttiioonn,, aanndd ccaappiittaall,, ooppeerraattiinngg,, aanndd mmaaiinntteennaannccee ccoossttss.. EEaacchh ttyyppee hhaass

aaddvvaannttaaggeess aanndd ddiissaaddvvaannttaaggeess..

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 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

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Fig 6.2-Horizontal Blower PDE

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77.. MMaaiinn PPaarrttss ooff PPDDEE

MMaanniiffoolldd

DDuusstt ccoolllleeccttiinngg hhooppppeerr

FFiillttrraattiioonn bbaagg

RRoottoorr && MMoottoorr

BBlloowweerr

SSttaappppeerr

CCaasstteerr WWhheeeell

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 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 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 OF THE PART REQ. QTY

1 * B POLYPROPYLENE BAG 4

2 X-9/7 B TENSION SPRING 4

3 B U" RIBBON - 1/4" 3MTR 1

4 B 3/8" THREAD BACKLITE KNOBS 6

5 * B ELE.OVER LOAD RELAY 2.5 TO 4 1

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 OF THE PART REQ. QTY

1 * B POLYPROPYLENE BAG 4

2 X-9/7 B TENSION SPRING 4

3 B U" RIBBON - 1/4" 2MTR 1

4 B 1/4" THREAD BACKLITE KNOBS 6

5 * B ELE.OVER LOAD RELAY 2.5 TO 4 1

Table-9.2

* Minimum Spares to be kept in stock

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10. Technical Specification

SSuuccttiioonn CCaappaacciittyy

(( 443300..6699 mm33// hhrr..))

FFiillttrraattiioonn AArreeaa

((0.4396 mm22))

DDuusstt SSttoorraaggee CCaappaacciittyy

((00..00004433 mm33))

IInnlleett CCoonnnneeccttiioonn

11 NNooss.. ooff DDiiaa ((3388..11mmmm))

PPoowweerr

00..55 HHPP // 22880000 RRPPMM // 33 PPhhaassee // 444400 VV // 5500 HHzz

OOvveerraallll DDiimmeennssiioonnss

331155 ((LL)) XX 331155 ((WW)) XX 445500 ((HH)) ((iinn mmmm))

11. Design Description

11.1 RRoottoorr SSppeecciiffiiccaattiioonn

IInnlleett DDiiaammeetteerr((DD11))==112200 mmmm

OOuuttlleett DDiiaammeetteerr ((DD22))==220000 mmmm

SSppeeeedd ooff RRoottoorr((NN))==22880000 rrppmm

VVeelloocciittyy ooff vvaanneess==uu11((mm//ss))

VVeelloocciittyy ooff aaiirr==VV((mm//ss))

VVaannee aannggllee(( ))==2200 ddeeggrreeee

WWiiddtthh ooff vvaannee((BB))==5500 mmmm

θ

20

Fig 11.1-Rotor

21

FFiigg 1111..22--FFiillttrraattiioonn PPllaattee

22

Fig 11.3-Storage Drawer(Dust Collecting Hopper)

23

Fig 11.4-Blower

24

Fig 11.5-Body of the PDE

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12. Calculation

1122..11 SSuuccttiioonn CCaappaacciittyy((QQ)) Velocity of vanes(u1) =

u1 =17.58 m/s Now θ =20 Velocity of air(V) = u1tanθ

V =

=17.58*tan20

V=6.39 m/s

Now

=3.14*6.39*0.120*0.05

=430.69 m3/hr

=7.178 m3/m

Q=240 CFM

12.2 Filtration Area

DDiiaa ooff FFiilltteerr HHoollee==110000 mmmm

LLeennggtthh ooff FFiilltteerr bbaagg==335500 mmmm

nn==NNoo.. ooff hhoollee

FFiillttrraattiioonn AArreeaa==

=3.14*0.100*0.350*4

=0.4396 m2

12.3 Dust Storage Capacity

CCss==LLeennggtthh((ll))**WWiiddtthh((ww))**HHeeiigghhtt((hh))

==228855mmmm**227755mmmm

==44331100662255 mmmm33

160D Nπ

=

0.120 280060

π ∗ ∗

17.58 tanθ

Dl nπ ∗

1Q v D Bπ= ∗ ∗ ∗

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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

µm.

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 high-

efficiency, 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 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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1144.. AApppplliiccaattiioonn::--

•• TToo RReemmoovvee ppoowwddeerr ffrroomm ttaabblleettiinngg mmaacchhiinnee..

•• TToo rreemmoovvee ssttiicckkeedd ppoowwddeerr ffrroomm ttaabblleett iinn ddee--dduusstt mmaacchhiinnee..

•• TToo rreemmoovvee ppoowwddeerr ffrroomm mmuullttii--mmiillll mmaacchhiinnee..

•• AAtt tthhee oouutt ppuutt ooff tthhee ggrraannuullaattoorr..

•• SSiimmiillaarr ccoonncceepptt iiss aallssoo uuttiilliizzeedd iinn Asphalt industry

•• TThhiiss ccoonncceepptt iiss uusseedd eevveenn iinn 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

•• wwwwww..wwiikkiippeeddiiaa..oorrgg

•• www.danthermfiltration.co.uk

•• www.camfilfarrapc.com

•• www.farrapc.com

•• www.milkeninstitute.org

•• wwwwww..tteecchhffllooww..nneett

•• wwwwww..ccmm11998811..iinn

•• wwwwww..ccaaddmmeecchh..iinn

•• wwwwww..fflluuiiddppaacckk..iinn

•• www.nfsrps.com

•• www.cimaindustries.com

•• www.bapihvac.com

Books Reference

•• FFlluuiidd mmeecchhaanniiccss aanndd HHyyddrraauulliicc MMaacchhiinneess bbyy RR KK BBaannssaall..