Air Clean Tower

In the traditional landscape of industrial air filtration, "capture at the source" using flexible suction arms has long been the gold standard. However, as manufacturing scales up, especially in the heavy machinery and steel structure sectors, traditional methods are hitting a physical ceiling.

When workpieces are tens of meters long and overhead cranes are in constant motion, ductwork becomes an obstacle rather than a solution. This is where the Air Clean Tower—a ductless, floor-standing, self-circulating industrial air purifier—is changing the game for large-scale welding environments.

Project Background

A leading manufacturer of heavy excavators and mining equipment recently faced a critical air quality challenge. Their main welding assembly hall, measuring 120 meters in length and 40 meters in width, was constantly filled with a lingering "blue haze" of welding fumes.

Workshop Conditions & Constraints

• Industry: Large-scale heavy machinery and transformer tank manufacturing.

• Facility Dimensions: 60m Length × 15m Width (Total area of 900㎡), organized into an 8-span layout.

• Workstation Mix: Comprises 10 manual welding stations, 1 robotic welding cell, and 2 manual grinding stations.

• Critical Pain Points: Complex infrastructure with existing pipelines and overhead cranes makes traditional fixed ductwork installation impossible.

Traditional industrial fume extractors with suction arms were deemed impractical because the arms could not reach the center of the large workpieces, and the necessary piping would interfere with the facility's logistics.

The Solution: Fume Extraction Air Clean Tower

After a technical site audit, the engineering team proposed a displacement ventilation strategy using multiple Air Clean Towers (Model LW-E series). Unlike traditional systems that pull air through pipes, the Air Clean Tower treats the workshop as a living ecosystem, continuously filtering and recirculating the entire volume of air.

Pollutant Types

• Welding Fumes: High-concentration metallic oxides generated from Argon Arc processes.

• Grinding Dust: Heavy abrasive particles and fine dust produced during metal finishing.

Product Solutions & Capture Strategy

• Core Filtration Units:

• LW-E-1609X-150B: Three "Air Clean Towers" for ambient self-circulating air purification.

• LW-E-1116EX: Centralized unit with a 75kW fan for multi-station integrated control.

• Capture Hardware:

• Automatic Hose Reels: 6-meter suction hoses for internal tank work, ensuring no floor obstructions.

• Flexible Suction Arms: 3-meter arms for precise source capture at manual welding stations.

• Side-Draft Hoods: Equipped with baffles for effective grinding dust containment.

• Intelligent Features: PLC-based smart control and automatic pulse-jet filter cleaning.

How It Works: The Clean Air Tower

The Air Clean Tower operates on the principle of layered air displacement.

1. Intake: The unit pulls contaminated air from the upper layers of the workshop where welding heat carries the fumes.

2. Filtration: The air passes through high-efficiency polyester filter cartridges with PTFE coatings, capturing 99.9% of sub-micron particulate.

3. Discharge: Clean, filtered air is discharged at low velocity through specialized diffusers at the base of the tower.

4. Circulation: This creates a "lake" of clean air at the floor level, which gradually displaces the rising fumes, pushing them toward the intake of the towers in a continuous loop.

Results & Client Feedback

After three months of operation, the facility underwent a third-party air quality audit. The results were definitive:

• PM2.5 Concentration: Reduced from 625 mg/m³ to an average of 289 mg/m³.

• Worker Satisfaction: Employee feedback indicated a noticeable reduction in respiratory complaints and a cleaner overall work environment.

Conclusion

As industrial facilities continue to grow in scale and complexity, the limitations of traditional duct-based extraction become more apparent. The Air Clean Tower represents the future of large-scale industrial fume extraction, offering a flexible, efficient, and intelligent alternative that meets the demands of 21st-century heavy manufacturing.

Is your workshop facing infrastructure constraints? Contact our engineering team today for a custom Air Clean Tower and air quality simulation.