Industries such as cement, mining and metals, chemicals and plastics, food and dairy, and power generation frequently handle materials that generate significant airborne dust and particulate emissions. Inadequate dust collection can compromise operational performance, reduce equipment lifespan, and negatively impact workplace safety and environmental compliance. Traditional systems often fall short due to manual oversight, reactive maintenance, and a lack of integration with broader plant automation systems.

The root cause of many dust collection inefficiencies lies in the limited capabilities of legacy monitoring and control systems. Plant operators cannot effectively monitor filter performance, manage compressed air usage, or predict system failures without real-time insights. This leads to various downstream effects: increased maintenance costs, excessive energy consumption, unplanned equipment downtime, and a higher risk of regulatory penalties due to emissions non-compliance.

Emerson has launched an intelligent Dust Collector Monitoring and Control Solution to address these challenges, integrating mechanical, control, and visualisation technologies into a unified, end-to-end automation platform.

Movicon.NExt SCADA HMIAt the heart of this solution are the software and interface capabilities that enable operators to make informed, real-time decisions and streamline dust collector performance. A central element of the solution is the Movicon.NExT SCADA platform, offering intuitive HMIs, remote monitoring, alerts, and data visualisation. Together with the PACSystems™ PLCs, RSTi-EP I/O modules and QuickPanel+ HMI, the system enables efficient control of multiple filter lines, real-time diagnostics, and predictive maintenance. Its scalable architecture can support systems of up to 500 pulse valves.

This solution aims to provide a comprehensive approach to dust collection, ensuring both operational efficiency and environmental protection.

The Benefits

By implementing Emerson’s intelligent Dust Collector Monitoring and Control Solution, industries can unlock a range of significant and measurable benefits:

• Reduced maintenance costs and total cost of ownership, driven by optimised filter cleaning, real-time diagnostics, and predictive maintenance strategies.
• Minimised energy usage and compressed air consumption through efficient pulse valve control and intelligent cleaning algorithms.
• Extended filter and valve life, translating to substantial cost savings—up to $18,000 USD per unit annually.
• Proactive detection of filter failures, to avoid costly penalties associated with non-compliance.
• Improved operational efficiency and reduced unplanned downtime, ensuring more reliable production and better equipment performance.
• Strengthened environmental compliance and asset protection, supported by accurate monitoring of dust levels and system conditions across the entire facility.

This comprehensive solution not only improves process reliability but also supports sustainability goals through more intelligent energy and emissions management.

To learn more about how Emerson’s complete automation ecosystem can modernise your dust collection, visit our website or contact us today.