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Category Archives: Soldering fume extractor

Categories Air Pollution Control, Fumekiller, Soldering fume extractor, Welding fume extractor Author poweradmin 0 Comments

Electrostatic vs Mechanical Filtration: A Comparative Study

The pressing need for cleaner, breathable air has given rise to numerous air pollution control mechanisms. Amidst this arsenal of tools, two stand out due to their popularity and efficiency: electrostatic filtration and mechanical filtration. Both these systems have their unique advantages, especially when applied to environments where pollutants like fumes from welding or soldering are prominent. This article delves into the comparative study of these two filtration techniques, shedding light on their mechanisms, applications, and suitability.

Mechanical Filtration: The Basics

Mechanical filtration operates on a simple principle: physically trapping particles using a filter. The air, laden with contaminants, is forced through a medium-often a fibrous material-where the pollutants are physically trapped. One of the most common applications of this technology is seen in the welding fume extractor and soldering fume extractor systems, where metal fumes and particulates are effectively removed to safeguard workers’ health.

Advantages:

  • Straightforward in design and operation.
  • Can trap large particles effectively.
  • Readily available and widely used in multiple industries.

Limitations:

  • The efficiency can drop as the filter gets clogged.
  • Regular maintenance and filter replacements are needed.
  • May not effectively remove ultra-fine particles.
  • Requires a higher power consumption because of the larger pressure drop.

Electrostatic Filtration: Charged Cleaning

Electrostatic filtration harnesses the power of electrical charges to remove pollutants. As the air passes through, particles are ionized (given a charge). These charged particles are then attracted to oppositely charged plates, ensuring they do not re-enter the atmosphere. This system is particularly efficient when it comes to capturing smoke, mist, and fine particulates, making it an optimal choice for a fume extractor in environments with volatile pollutants.

Advantages:

  • High efficiency of 90–95% in capturing small particles.
  • Less airflow resistance, resulting in significant energy savings.
  • Long-lasting filters with little to no replacements in the lifetime of the system.

Limitations:

  • Efficiency can be affected by humidity and certain types of particles.
  • Initial costs may be higher than mechanical filters.

Which is Right for You?

Choosing between electrostatic and mechanical filtration often hinges on the specific application and the nature of the pollutants.

For environments like welding or soldering stations where there’s a mix of large and ultra-fine particles, a hybrid approach might be ideal. For instance, utilizing a welding fume extractor with mechanical filters to capture larger debris and an electrostatic stage to handle the finer particulates can offer comprehensive air pollution control.

On the other hand, in environments where ultra-fine particles dominate, an electrostatic fume extractor is the best bet, offering high efficiency and longer-lasting filtration.

Conclusion:

Both electrostatic and mechanical filtration have their places in the toolkit of air pollution control. Understanding the nuances of each, their strengths, and limitations, is key to deploying the right solution for your environment. Whether you’re soldering delicate electronics or welding large metal structures, there’s a filtration solution optimized for your needs.

With the increasing importance of ensuring clean, pollutant-free air in our workspaces, investments in efficient and effective filtration systems are not just beneficial but crucial. Make sure to consider the type of pollutants, their sizes, and the frequency of exposure when making your choice between these two stalwarts of filtration technology.

Categories Fumekiller, Soldering fume extractor Author poweradmin 0 Comments

Individual Soldering Fume Extractors for Single Soldering Stations

Even though the number of individual hand soldering or dip tinning stations are several in any assembly floor, many users prefer to use individual fume extractors for each station. This is for maximum flexibility during re-organising the stations according to the requirement of the day. The soldering station can be located elsewhere along with its dedicated fume extractor.

For individual soldering stations where relatively smaller components are soldered, we suggest the use of our Fumekiller® electrostatic soldering fume extractor model FK250 single pass filtration unit or the recommended FK250DP, dual pass fitration unit to be placed below the soldering station table. To capture the soldering fumes during soldering, we suggest the use of our self-balanced segmented extractor mini arm fitted to the edge of the table opposite to the operator seat.

The segmented self-balanced mini arm can be positioned as close as 3 to 4 inches from the fume generation spot to optimise the capture of fumes as well as operator comfort. During soldering the fumes are captured by the mini arm and routed to the Fumekiller® unit. Suction is provided using a low noise, high efficiency suction fan in the Fumekiller® unit.

Soldering fumes consists of fine particulates such as lead, flux, carbon, etc which are trapped in the Electrostatic filter modules and the clean air is released through the exhaust port.

For soldering of relatively larger components, possibly with multiple soldering spots such as larger PCBs, we suggest the use of a specially designed small SS booth with in-built lighting and an exhaust port on top of the booth. Here there is no requirement of the mini arm for capture of fumes. The exhaust port is connected to the Fumekiller® unit using PVC flexible hose.

The soldering is carried out within the booth confines. The fumes are sucked through the exhaust port and the particulates are filtered by the Fumekiller® unit.

Please note that the above are arrangements for soldering fume extraction using individual fume extractors each dedicated to a single soldering station.

Fume Working
Categories Fumekiller, Soldering fume extractor, Welding fume extractor Author poweradmin 0 Comments

Understanding the Mechanics of the FumeKiller® Fume Extractor

Understanding the Mechanics of the FumeKiller® Fume Extractor

In today’s industrial landscape, where the importance of clean and safe working environments is paramount, investing in efficient air pollution control equipment like a quality fume extractor is not just an option but a necessity. The Fume Extractor unit designed and developed by Powertech Pollution Controls and marketed under the brand of FumeKiller®, stands out as an exemplar in this domain, designed to safeguard the health of employees and ensure optimum operational efficiency in diverse industrial settings.

How Does the FumeKiller® Work?

The FumeKiller®, a top-of-the-line welding fume extractor and soldering fume extractor, that operates on the straightforward yet effective principle of electrostatic precipitation. Each unit is equipped with electrostatic filtration modules for filtration of air that passes through. The filter modules are 2-stage electrostatic filters, where the first stage consists of parallel plates that are charged at a voltage of 10kV and the second stage consists of plates that are alternatively charged (positive and negative) at 5kV. When any kind of fumes, smoke, mist, or dust passes through the FumeKiller®, the particulate matter is charged with a heavy positive charge in the first stage. When passing through the second stage of filtration, the positively charged particles stick on the to the negatively charged plates after which the filtered air is let out from the outlet.

The FumeKiller® extracts the contaminated air from the workplace, purifying it from harmful fumes and particles and then releasing clean air back into the environment. This cycle ensures the consistent maintenance of a wholesome working atmosphere, protecting workers from potential health hazards associated with prolonged exposure to industrial fumes and contributing significantly to air pollution control.

Advantages of using the FumeKiller®:

As a fume extractor, what sets the FumeKiller® apart from the regular mechanical filters is the pressure difference. Mechanical filters require more pressure difference to be created on either side of the filter to ensure effective filtration of the fume or dust particles. On the other hand, the FumeKiller® units do not have any blockage on the path of the air flowing through it, which directly implies that the pressure difference is significantly lower. Because of this, the FumeKiller® units also boast a significant reduction in the power consumption for their operation.

The FumeKiller® has a high-efficiency of filtration, effectively filtering over 90 – 95% of fume or dust particles that pass through it. In particular, the device’s efficiency in dealing with welding and soldering fumes, marks it as an invaluable asset for industries engaged in these operations.

The Significance of Investing in a Quality Fume Extractor

Why should industries prioritize incorporating a fume extractor like the FumeKiller into their operations? Beyond ensuring compliance with occupational health and safety standards, a high-quality fume extractor plays a pivotal role in protecting the well-being and productivity of employees. By mitigating exposure to harmful fumes, businesses can reduce health-related absenteeism and medical expenses, ensuring a more productive, healthier, and more satisfied workforce.

The FumeKiller® Fume Extractor: A Step Towards Optimal Air Pollution Control

In a world where industries are increasingly held accountable for their environmental footprint, investing in a quality welding fume extractor or soldering fume extractor like the FumeKiller® is a progressive step. The device’s efficiency in purifying air aligns with global efforts towards better air quality, showcasing a company’s commitment to environmental sustainability and the welfare of its employees.

Categories Fumekiller, Soldering fume extractor Author poweradmin 0 Comments

FumeKiller® applies as soldering fume extractor in a semi-centralised fume extraction system

At Powertech Pollution Controls Pvt Ltd, we provide a variety of mobile and fixed fume capture devices, under the brand name of Fumekiller® that are well-suited to capture most types of fumes, smoke, mist and fine dust from generating sources. Our Fumekiller® devices can be used for hand-soldering, wave-soldering, dip-tinning, automated soldering stations, etc. These fume extractors can be designed with suitable ducting and suction hoods to suit centralised as well as semi-centralised extraction .

Some of our reputed customers include India Nippon, Delta Electronics, Secure Meters, Lucas TVS, Centum Electronics, Rakon India among others.  

In an air-conditioned room, our client had 5 rows of soldering stations, where hand soldering was carried out on tables with the operators sitting in front. Each row of tables consisted of 10 soldering stations. With a calculation of 200 cubic meters per hour per station, it was decided that for the soldering fume extractor we would use the FumeKiller® model FK2000DPEM/1.5hp, which was then positioned at the head of the row of tables, mounted on anti-vibration mounts. PVC rigid pipes were used as ducting and routed below the tables throughout the length, covering the 10 stations.

At each soldering station, a duct break was introduced in order to provide a self-balanced flexible segmented suction arm with a suction hood for the capture of soldering fumes. Ten such arms were provided, one for each station. The arms could be positioned easily as required, with the suction hood placed about 5 – 6 inches from any soldering fume generation spot.

For 5 rows of tables, 5 no.s of Fumekiller® units were positioned, one at the head of each row  with ducting as mentioned above. During soldering the fume extractor was switched on. From each soldering station, the fumes generated were sucked through the suction hoods / arms and reached the fume extractor through the ducting provided. The soldering fumes were trapped by the electrostatic filtration system and the clean air released from the exhaust of the fume extractor into the room. Air-conditioned air was preserved from loss because of this arrangement.   

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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