Definition of Problem
During the uncoiling process of steel coils, a high concentration of scale dust is released into the working environment. The employer’s initial requirement was to achieve at least 70% dust collection efficiency.
Before entering the Continuous Pickling Line (CPL) and flash butt welding line, scale residues on the steel coils are removed by a scale breaker crushing machine. This area generates intense dust emissions into the workplace.
Additionally, the CPL line includes a 600-amp flash butt welding machine. During welding operations, significant amounts of sparks, slag and high-density welding fumes are released into the environment.
Process of Solution
To manage the intense dust and fume problem, the employer had been conducting three-shift maintenance shutdowns once per week for cleaning and ventilation purposes, resulting in substantial production losses and financial costs.
Our process expert teams conducted detailed on-site observations and identified five primary emission points where scale dust was spreading into the environment.
For these zones, high-efficiency slot hoods were engineered to increase capture velocity and maximize extraction performance without disrupting operations.
To address the heavy welding fumes, a triangular flame arrestor fabricated from special spark-resistant fabric was designed. Welding fumes were captured through a 200×2000 mm hood, then passed through a horizontal cyclone spark arrestor to ensure pre-filtration and simultaneous protection against potential filter fire risks.
The filtration unit selected for the system was a jet-pulse cartridge filter with 8,000 m³/h capacity.
Installation and Initial Results
The extraction systems were designed, manufactured and installed by FRESHWELD’s expert engineering teams.
An airflow rate of 5,000 m³/h per hood was calculated for five extraction hoods. Accordingly, a 25,000 m³/h jet-pulse bag filter unit was integrated into the system.
The total system pressure loss was calculated at 6,000 Pa, including the filtration unit.
Long-Term Success
Although the customer initially expected 60% efficiency in collecting scale dust waste, the system achieved 65–70% collection efficiency, significantly improving workplace air quality. Weekly maintenance shutdowns were reduced from three shifts to a single shift.
The reduction in production downtime, combined with improved worker health and operational continuity, resulted in high employer satisfaction.
Sectoral Analysis
(Steel & Iron Industry)
The steel processing sector typically operates in large-scale industrial facilities and represents a critical component of heavy industry manufacturing.
Many facilities face common challenges in managing dust, fumes and particulate emissions generated during coil processing operations. Processes such as uncoiling, cutting, forming and welding can release scale dust and welding fumes that negatively affect workplace air quality. As a result, the industry continuously seeks solutions to improve occupational health and safety standards.
Metal processing plants are investing in enhanced industrial ventilation systems, advanced filtration technologies and optimized extraction units to improve dust and fume management. These measures contribute to more sustainable and healthier industrial working environments across the sector.
Conclusion and Evaluation
This and similar successful dust and fume control solutions provide substantial benefits in terms of production continuity and worker health protection.
Through the implementation of innovative extraction engineering solutions, a breathable workplace environment was achieved and working conditions were improved to desired levels. The reduction in maintenance-related downtime further increased employer satisfaction and strengthened operational continuity.
Developing shared solutions for common dust and fume challenges in the Steel & Iron sector represents an important step toward improving occupational health and safety standards and creating healthier industrial environments.
These achievements emphasize the importance of sector-wide collaboration and innovative engineering solutions.
FRESHWELD Solutions for Production Line Industrial Ventilation
Resources:
- https://www.csgb.gov.tr/media/1335/i%C5%9F-sa%C4%9Fl%C4%B1%C4%9F%C4%B1-ve-guevenli%C4%9Fi-uygulamalar%C4%B1.pdf
T.C. Çalışma ve Sosyal Güvenlik Bakanlığı, İş Sağlığı ve Güvenliği Uygulamaları Rehberi, Sayfa 62