Development of welding multi-station electrostatic dust purification system

**I. Overview** The welding training center typically features a multi-station welding workshop designed for welder skill development. Due to the high number of stations and the significant amount of welding fumes generated, effective smoke treatment is essential. Currently, most domestic welding training workshops use centralized fume treatment systems. Common methods include straight-row, bag-type, filter-tube, and electrostatic purification systems. The straight-row system usually doesn’t purify the fumes before discharging them directly outside, which can lead to local air pollution. It’s generally used in venues with fewer stations. Bag-type and filter-tube systems offer better centralized purification, making them more common in training centers. However, they require frequent filter replacements and have higher maintenance costs over time. The electrostatic system is often used on a single machine basis, where the purified air is recirculated indoors, which may increase indoor temperatures during summer. Both the straight-row and bag-type systems can significantly lower room temperature due to heat being drawn out, especially in northern regions. To address these challenges, our company has developed a new system combining split electrostatic cleaning with multi-station centralized discharge. This innovative approach has proven highly effective. This paper presents an example of the large-scale welding training workshop at the Daqing Oilfield Welding Training Center, showcasing this new welding fume purification system. **II. Overall Design** 1. **Training Plant Design Requirements** The Daqing Oilfield welding workshop training center consists of 98 welding stations, each measuring 2.2m × 2.2m. The facility is primarily used for employee welding skill training and also hosts provincial and national welding competitions. It requires strict control of indoor smoke, high noise standards, and comfortable winter heating conditions. The varying number of participants daily leads to fluctuating station usage. Additionally, the layout must consider visibility for supervisors, fire safety, and routine maintenance, making it one of the largest, highest-standard welding training facilities in the country. 2. **Overall Layout Design** To avoid energy waste from full operation of the purification system when only some stations are in use, the dust removal system is divided into zones based on the station layout. After calculating total exhaust volume and evacuation requirements, the 98 stations are divided into seven zones, each containing 14 stations arranged in two rows. Each zone has a centralized electrostatic fume purification system, serving seven welding stations. **III. Purification Principle and System Composition** 1. **Purification Principle** The electrostatic welding fume purifier uses a fan's gravitational force to draw in the welding fumes. A microfiltration filter performs coarse filtration, followed by an ionization zone where charged particles are captured. Odorous organic gases are adsorbed by an activated carbon unit before being discharged. The multi-station electrostatic dust purification system is based on the principle of a single-unit electrostatic purifier. After redesign, it is placed above each station, connected via shared ducts. Each station has an independent switch for regional purification and management. 2. **System Composition** The system includes closed stations, electrostatic purification units, exhaust ducts, fans, exhaust vents, and an electronic control system. Each station is fully enclosed, with air inlets at the bottom and outlets at the top. The purification unit contains pre-filters, dust collection drawers, and a pulse cleaning system. Exhaust pipes are designed step-by-step, and fans create negative pressure to draw air into the system. The exhaust vent allows for either outdoor or indoor reflow. The electronic control system ensures safe and efficient operation. **IV. Key System Technologies** 1. **Technical Improvements in the Electrostatic Purifier** The purifier was redesigned by removing the fan and suction arm, retaining only the filtration function. The inlet and outlet were modified, connecting directly to the station's outlet. This improved efficiency and reduced complexity. 2. **Flue Gas Concentration System** Each system has an exhaust fan that serves multiple purification units. Fans are installed in a central location for easy maintenance. Low-resistance PVC ducts and adjustable valves ensure balanced airflow. Noise reduction measures, such as soundproof rooms and mufflers, were implemented to meet national standards. 3. **Dust Cleaning System** A convenient cleaning system was designed, featuring a closable tank and water pipes above each station. This reduces labor and avoids secondary pollution caused by airborne dust. 4. **Energy-Saving System** During winter, part of the purified air is recirculated to maintain indoor temperature, reducing heating load. In summer, air is directly discharged outside. Centralized ventilation groups help save energy when station usage is low. **V. Conclusion** The multi-station electrostatic dust purification system was developed based on the working principle of a single electrostatic cleaner. It effectively controls welding dust, solves issues like temperature control, cleaning, and noise, and has received several national utility model patents. The Daqing Oilfield Welding Training Center successfully implemented this system, hosting the 3rd National Staff Professional Skills Welding Competition. The system’s success highlights its potential to revolutionize welding fume removal in training workshops.

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