EP 28 PROTECT:
Custom solution for combustible metal grinding dust
The EVOTEC EP 28 PROTECT was developed as a custom solution for extracting flammable, potentially explosive grinding dust from metal . The system is used in a grinding process for turbine wheels and combines high-performance extraction technology with comprehensive safety features – including an automatic extinguishing system, flameless pressure relief, volume flow control, fill level monitoring, and controlled filter cleaning.
| Project Profile | |
|---|---|
| Application | Grinding Process for Turbine Wheels |
| Medium | flammable, potentially explosive metal grinding dust |
| Solution | Custom EP 28 PROTECT Special System |
| Control | PID control with flow rate regulation and process monitoring, interface for customer-side connection |
| Safety Concept | Fire suppression system, flameless pressure relief, check valve, and automatic shutdown |
| Filter Technology | M filter cartridges with automatic compressed-air cleaning and an additional H filter cassette |
| Waste Disposal | Lowerable VA stainless steel waste container with swivel casters and fill-level monitoring |
| Integration | Tailored to customer processes, media, and existing production environments; interface with control technology |
Industrial grinding processes generate very fine dust—some of which is potentially explosive—depending on the material .
Standard solutions are often insufficient, particularly when dealing with metallic grinding dust, since, in addition to simply capturing the dust, it is also necessary to protect operators, machinery, and the production environment.
For a customer in the turbine machining sector, the EVOTEC EP 28 PROTECT was developed as a custom solution. The system is designed for the safe extraction of flammable metal grinding dust and is used directly in a grinding process for turbine blades.
The focus was on three requirements:
- Reliable data collection during the process
- a high level of operational reliability in a live production environment and
- A multi-level safety concept for explosion protection.
Customized Exhaust Solution for Zone 22
The EVOTEC EP 28 PROTECT was designed for safe use in ATEX Zone 22.
The system is not a standard machine from a catalog, but rather a custom design developed specifically for this project, featuring specially configured safety and control components.
Especially when dealing with flammable metal dusts, simply increasing the suction power is not enough.
The key lies in the interplay between detection, filtration technology, monitoring, pressure relief, fire suppression systems, and control.
Only when these components are tailored to the specific process can a solution be created that functions safely and reliably in everyday industrial operations .
Check Valve Connection
Low-maintenance, leak-proof locking mechanism
Dirt container with fill-level monitoring
Integrated Fire Suppression System
Automatic and manual fire suppression system with dry chemical powder
A key safety feature of the system is the integrated D-powder fire suppression system. It is specifically designed for the material being extracted and the associated fire hazards posed by combustible metal dusts.
In the event of a fire, the fire suppression system is automatically activated by the system control unit. At the same time, the system is shut down in a controlled manner to ensure that the process is safely interrupted and that no further movement of air or dust exacerbates the hazardous situation. The fire suppression system, sensors, control system, and shutdown logic are all coordinated to form a unified safety concept.
In addition, a manual activation feature is provided. This allows the fire suppression system to be activated directly at the system itself, independently of the automatic system, if a situation on site requires immediate action.
Flameless pressure relief to protect equipment and production
A key safety feature is the side-mounted flameless pressure relief system. It is designed so that, in the event of an incident, the resulting explosion pressure can be safely vented from inside the system without allowing flames to escape uncontrolled into the production area.
A rupture disc is used inside the system. If a specified pressure is exceeded, the rupture disc opens and allows pressure to be relieved. The resulting pressure is then vented via the flameless pressure relief element. This component is designed to specifically reduce both pressure and the effects of flames before they are released into the surrounding area.
One notable feature is its lateral positioning on the separate support frame. This design was deliberately chosen to ensure as much free space as possible around the pressure relief mechanism. In the event of an incident, this allows pressure to escape in multiple directions and dissipate in a controlled manner.
This design protects not only the extraction system itself but also the adjacent production area. Especially when dealing with explosive metal grinding dust, this unobstructed relief area is a crucial part of the safety concept. The pressure relief system, rupture disc, fire suppression system, sensors, and control system are coordinated with one another and designed for the specific material being extracted.
Level Monitoring and Retractable VA Debris Container
The waste disposal system was also integrated into the security and surveillance concept of the EP 28 PROTECT . A fill-level sensor detects when the container reaches a critical fill level and automatically transmits this information to the system control unit.
This allows for an early response before operational disruptions or unsafe conditions arise. Monitoring thus not only supports process safety but also ensures the predictable and controlled disposal of the extracted material.
The debris container is made of sturdy VA stainless steel and can be lowered for removal. Thanks to the integrated swivel casters , it can be easily rolled out of the system after being lowered . This simplifies the disposal of the extracted metal dust and reduces the manual effort required when changing the container.
This solution offers a significant advantage, particularly when dealing with safety-critical dusts: The container can be removed in a controlled, ergonomic manner with minimal material movement. This simplifies maintenance and facilitates the safe handling of the collected material.
Tight System Shutdown
The system is equipped with sturdy quick-release fasteners. These allow the housing components to be opened and closed quickly, but can also be adjusted manually.
This is important to ensure that the system remains leak-free over the long term. Especially when dealing with fine grinding dust and safety-critical applications, sealing must not be left to chance.
Compressed Air Cleaning with Interval and Follow-Up Cleaning
An automatic compressed-air cleaning system is integrated to ensure consistently reliable operation. The filters are cleaned at set intervals. In addition, a post-cleaning function is provided so that dust can still be removed from the filter even after the unit has stopped running.
This reduces maintenance requirements and helps ensure consistent suction power over extended periods of use.
(Fig.: illustrative diagram)
Check valve
The system is also equipped with a check valve.
It serves as an additional protective component within the system design and helps ensure a safe separation between the process and the exhaust system.
If the check valve is triggered, it sends a signal to the system control via an interface. The system is then automatically shut down.
PID Control with Flow Rate Regulation
The heart of the EP 28 PROTECT is the integrated PID controller with flow rate control. It connects the individual safety and system components into a coordinated overall system and ensures that the extraction system not only operates at high performance but also continuously monitors and actively controls the process .
The extraction capacity is not set at a fixed level but is controlled based on the process. Especially in grinding processes involving flammable metal dusts, a stable flow rate is crucial to ensure that the dust generated is reliably captured and safely removed. The control system continuously monitors the system’s status and adjusts the extraction capacity to meet the requirements of the customer’s process.
The control system integrates several key functions of the system: airflow control, filter cleaning, fill level monitoring, the fire suppression system, automatic shutdown in the event of a fire, and other safety functions. As a result, the components do not operate in isolation from one another but are specifically coordinated during operation.
A particular advantage lies in the process-oriented design. The control system was tailored to the specific grinding process and the medium to be extracted. The result is a solution that not only adapts technically to the application but can also be integrated into the customer’s existing production and safety systems.
This brings the EP 28 PROTECT into a customized, comprehensive solution: The system automatically detects, monitors, controls, and responds to defined operating conditions. This increases process reliability, ensures consistent extraction performance, and guarantees that safety functions are triggered in a controlled manner in the event of an incident.
Custom Machine Building Instead of Standard Solutions
The EVOTEC EP 28 PROTECT demonstrates what an extraction system can look like when it is precisely tailored to a specific process. For combustible metal grinding dusts, it’s not just the airflow rate, filter area, and motor power that matter. What’s crucial is the overall concept, which includes process integration, safety features, controls, and ease of maintenance.
This is precisely where the strength of custom machine building lies: The system is not cobbled together around the process, but is designed from the outset to suit the specific application.
Key points of the special solution:
- Design for combustible, potentially explosive metal grinding dusts
- Application in a grinding process for turbine wheels
- Integrated fire suppression system with dry chemical powder
- Automatic and manual activation of the fire suppression system
- flame-free pressure relief
- PID Control with Flow Rate Regulation
- Level Monitoring in the Waste Container
- Automatic compressed air cleaning with interval and follow-up cleaning
- Adjustable quick-release fasteners for a tight seal
- Rugged design for industrial production environments
With the EVOTEC EP 28 PROTECT , a highly specialized extraction solution was implemented for a safety-critical grinding process. The system combines industrial-grade extraction performance with a comprehensive safety concept and demonstrates how custom machine building works in practice.
For processes involving flammable or explosive dusts, a case-by-case assessment is crucial. The material, dust behavior, process control, installation location, and safety requirements must all be evaluated together. Only then can an extraction solution be developed that is technically suitable and functions reliably during operation.
Your Partner for Industrial Exhaust Solutions with Explosion Protection
EVOTEC develops extraction systems and industrial vacuum cleaners for industrial applications and produces not only production-ready units but also custom solutions tailored to specific applications. Our systems are designed for process reliability, durability, and individual requirements.
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Submit a non-binding inquiry or schedule a personal consultation—we’d be happy to help!
Robin Buschbaum
Sales D/A/CH
Specialist for extraction technology
vertrieb@evo-products.de
02642 9373-53
Lars Blankenburg
Sales
lars.blankenburg@evo-products.de
02642 9373-10
Asim Zaman-Pahlke
Export Sales
export@evo-products.de
02642/9373-15