Welding fumes, grinding dust, metal vapor, and ultra-fine particles pose risks to worker health, product quality, equipment longevity, and fire safety in metalworking facilities.
1. Health Risks by Particle Size
- >10 microns (coarse): trapped in the nose and throat, causing upper respiratory irritation
- 5–10 microns (PM10): enters the trachea and bronchi, increasing bronchitis risk
- <2.5 microns (PM2.5): penetrates deep into the alveoli, associated with pulmonary fibrosis and chronic respiratory disease
- <0.1 micron (ultrafine): enters the bloodstream, affecting the nervous and cardiovascular systems
Welding Fume Composition
- Fe2O3 (iron oxide), MnO (manganese oxide), SiO2 (silicon dioxide)
- Cr6+ (hexavalent chromium) from stainless steel welding — carcinogenic
- Ni and Zn from galvanized steel welding — risk of metal fume fever
Per QCVN 02:2019/BYT, occupational exposure limits require manganese concentration ≤0.2 mg/m³ and total respirable dust ≤3 mg/m³ per shift.
2. Dust Collection System Types and Applications
Cartridge Dust Collector
- Suited to MIG/MAG/TIG welding and plasma cutting
- >99.9% efficiency for 0.3-micron particles
- Automatic Pulse-Jet cleaning
- PTFE-coated polyester media for ultra-fine dust and anti-clogging performance
Bag Filter Dust Collector
- Suited to grinding, polishing, and metal cutting with heavy coarse dust loads
- Handles large airflow volumes (>5,000 m³/h)
- Lower bag replacement cost
- Lower efficiency for ultra-fine dust compared to cartridge systems
Mobile Welding Fume Extractor
- Suited to standalone welding stations or small workshops
- Captures fumes at the source, reducing worker inhalation risk
- Integrates HEPA H13 and activated carbon for fine dust and odor control
Centralized Ducted System
- For plants with multiple welding and cutting stations
- Connects extraction points via ductwork to a central dust collector
- Requires airflow, duct sizing, and static pressure calculations
3. ATEX Explosion Safety Requirements
Aluminum, magnesium, and titanium dust pose a combustion risk at certain concentrations. Dust collectors handling these materials must:
- Meet ATEX Zone 22 requirements per IEC 60079-31
- Include a spark arrestor installed before the filter unit
- Be equipped with an explosion isolation valve and explosion vent
- Be fully grounded to eliminate static buildup
4. Air Filtech Mechanical Workshop Solutions
- Cartridge dust collectors with PTFE membrane, automatic Pulse-Jet system, and optional HEPA after-filter
- Mobile welding fume extractors with integrated HEPA H13 and activated carbon
- Pulse-Jet bag filters for grinding dust, steel filings, and heavy metal dust
- Spark arrestor solutions and ATEX-compliant consulting for aluminum, magnesium, and titanium workshops
- Centralized ducted dust collection system design with airflow/pressure calculation and duct optimization
5. Featured Projects
- COMA Construction Mechanical Corporation (Hanoi) — centralized dust collection for 12 welding stations, 15,000 m³/h capacity
- Đông Anh Mechanical Factory (Hanoi) — HEPA H13 filters for a steel plate plasma cutting system
- Kim Phát Aluminum Casting Co., Ltd. (Bình Dương) — ATEX-compliant dust collection system for a high-pressure aluminum die-casting workshop
Contact Air Filtech: 08 999 44 666 | info@airfiltech.vn
