Comprehensive Analysis of Welding Fume Purification Technology: High - efficiency Treatment Solutions and Application Scenarios

 

During welding operations, the generation of fumes and harmful gases poses a serious threat to the health of workers and the environment. This article systematically analyzes the core processes and equipment selection strategies of welding fume purification technology to help enterprises achieve high - efficiency treatment and environmental compliance.

 

I. Centralized Central Welding Fume Dust Removal System

Applicable Scenarios: Large - scale welding workshops (such as shipbuilding, construction machinery production lines) and modern factories with multi - station collaborative operations.

Technical Highlights:

1. Intelligent Capture System: Through the modular pipeline network and negative pressure balancing technology, a 100% fume capture rate at welding stations can be achieved, which is especially suitable for high - intensity welding at fixed stations.

2. Multi - stage Purification Unit:

   - Cyclone Pre - filtration: Intercept large - particle dust larger than 10μm.

   - High - voltage Electrostatic Dust Removal: Remove sub - micron suspended particles from 0.1 to 10μm.

   - Activated Carbon Adsorption Layer: Degrade harmful gases such as ozone and nitrogen oxides, and eliminate the odor of welding fume tar.

3. AI - driven Energy - saving Design: The variable - frequency control system adjusts the air volume according to the real - time working conditions, saving more than 30% of energy compared with traditional equipment.

 

II. Mobile Welding Fume Purifier

Applicable Scenarios: Small - scale welding stations, equipment maintenance workshops, and work scenarios that require frequent movement (such as construction sites).

Core Advantages:

1. Precise Fume Capture: The 7 - joint universal suction arm system supports three - dimensional spatial positioning, with a coverage radius of up to 2 meters, increasing the fume collection efficiency by 40%.

2. Medical - grade Purification Standard:

   - The HEPA - Ultra filter element has a retention rate of over 99.95% for 0.3μm particles.

   - The fire - retardant mesh design (aperture ≤ 5mm) effectively prevents safety hazards caused by welding sparks.

3. Convenient Operation and Maintenance Design:

   - The lightweight alloy frame allows for single - person movement.

   - The magnetic dust collection drawer simplifies the cleaning process.

 

III. Combined Fume Treatment Process

For complex working conditions (such as container welding and laser cutting), a composite solution of "source control + hierarchical purification" is recommended:

1. Source Reduction Technology:

   - Use low - fume welding wire materials.

   - Optimize welding parameters to reduce fume generation.

2. Hierarchical Collection System:

   - Fixed Top Suction Hood: Suitable for automated welding lines, with a hood opening air velocity of ≥ 1.2m/s and a height of 0.5 - 0.8m from the weld.

   - Bottom Blowing and Suction Device: For large - scale workpiece welding, improve the collection efficiency through airflow guidance.

3. Comprehensive Purification Module:

   - Filter Cartridge Dust Removal Unit: Treat visible fumes with a particle size > 5μm.

   - Chemical Absorption Tower: Neutralize acidic gases (such as nitrogen oxides).

   - Ultraviolet Catalytic Oxidation: Decompose volatile organic compounds (VOCs).

 

IV. Technological Innovation and Environmental Benefits

1. Internet of Things Monitoring System: Display real - time data such as PM2.5 and harmful gas concentrations, and issue automatic warnings when the standards are exceeded.

2. Energy - consumption Optimization Scheme:

   - The branch pipe air volume balancing valve reduces system resistance.

   - The variable - frequency fan starts and stops according to the welding signal, reducing no - load energy consumption.

3. Economic Calculation:

   - Although the initial investment of the centralized system is relatively high, the energy and maintenance cost savings within 3 - 5 years can recover the investment.

   - The annual maintenance cost of a single - station mobile device is reduced by 60%.

 

V. Equipment Selection Guidance and Suggestions

1. Match the Air Volume According to the Welding Process:

   - CO₂ shielded welding: 800 - 1000m³/h/station.

   - Submerged arc welding: 1500 - 2000m³/h/station.

2. Spatial Layout Criteria:

   - Keep the main pipeline flow velocity at 18 - 22m/s.

   - If the distance between adjacent stations is > 2m, additional collection points need to be added.

3. Operation and Maintenance Management Specifications:

   - Replace the HEPA filter element every 500 hours.

   - Check the saturation rate of the activated carbon adsorption layer quarterly.