
Expanded polystyrene and CNC milling: managing EPS dust and preventing explosive atmospheres in indoor environments
Expanded polystyrene (EPS) is created through a two-step transformation of polystyrene granules. These granules are exposed to heat, chemicals, and water vapour, causing the gas within them to expand. This results in an increase in volume by up to 40 times the original size. The expanded granules are then compressed into large blocks.
EPS is widely used across various industries due to its desirable properties: it is lightweight, has low thermal conductivity, is resistant to weathering, and is chemically stable. These features make it ideal for applications such as packaging, architectural profiles, and in the construction industry, where it is used in wall panels and shapes for thermal and acoustic insulation.
The raw polystyrene blocks can vary in density depending on their intended use and undergo several processing steps, including:
- Squaring and cutting using CNC (Computer Numerical Control) machines,
- Shaping to create custom forms,
- Sculpting to produce complex shapes with intricate details,
- Decoration and finishing for specialized applications.
EPS can also be ground into smaller granules, which can be recycled into secondary raw materials for uses such as lightweight aggregates, soil conditioners, or even energy production due to its high calorific value (for example, 1 kg of EPS can replace 1.2-1.4 liters of fuel oil).
Given the versatility of its applications, polystyrene is therefore an extremely interesting material in terms of performance. However, the abundant quantity and variable conformation of the dust generated during its processing poses certain critical issues - including the risk of generating potentially explosive atmospheres and the need to have adequate filtration systems capable of handling the waste.
While EPS is an incredibly versatile and useful material, the dust generated during its processing presents significant challenges. The fine dust particles can pose a safety risk, as they are combustible and could create potentially explosive atmospheres. Additionally, effective filtration systems are required to manage this waste and reduce the risks associated with dust accumulation.
Confined indoor spaces and potentially explosive atmospheres: a case study
A Slovenian manufacturer of EPS processing machinery approached TAMA Aernova to design and implement a filtration system for one of its clients.
TAMA Aernova developed a custom solution, overseeing every step from initial design to installation and producing a unit that optimises space in terms of walkable area while ensuring high standards of performance and safety.
For this project, the PULCO AIR ATEX bag filter was chosen. This dust collector is designed to manage air flows with high pollutant content, in this case to handle dust generated by the shredding and sorting of polystyrene.
The filter features a pneumatic cleaning system, activated by a differential pressure switch, that efficiently separates coarse dust from the filter elements. The residual EPS dust is then safely discharged through an ATEX star valve.
An important aspect of the system design was ensuring the filter could be safely located indoors. To address the risk of explosion, the filter was equipped with flameless explosion venting devices, which allow for the controlled release of excess pressure in line with safety standards for enclosed spaces.
Thanks to TAMA Aernova's technological expertise and focus on safety, the solution provided meets the customer's needs by creating a safe, efficient working environment. The system not only performs effectively but also ensures compliance with environmental regulations.
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