DESIGN OF LOCAL EXHAUST

VENTILATION

This note is designed to give guidance to project engineers, plant engineers or

mechanical engineers on the approach to and specification of LEV Design.

This document supports ICI Group SHE Guideline GG 10.1.1

This document has been produced by:

Colin Heijne, ICI C&P Occupational Health

John Wilkinson, Zeneca Engineering
Peter Harrington, ICI Engineering Technology

Issued by: Group SHE Department

Approved by: Group Occupational Health Committee

© Imperial Chemical Industries plc 1996

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 Table of Contents

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 EMISSION CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 CONTROL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 DESIGN OF CAPTURE HOODS AND BOOTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 EXTRACTION VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 EXTRACTION SYSTEM DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7 SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

APPENDICES

A LOCAL EXHAUST VENTILATION SYSTEM DESIGN CHECKLIST . . . . . . . . 14

B EXAMPLES OF HOOD DESIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TABLE

1 EXAMPLES OF CAPTURE VELOCITIES REQUIRED FOR DIFFERENT

TYPES OF EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FIGURES

1 INFLUENCING FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 DISPLACED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 CAPTURE VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 POOR VELOCITY DISTRIBUTION AND EXCESSIVE TURBULENCE DUE
TO A SINGLE POINT EXTRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 EVEN DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 TURBULENCE AT EDGES AND THE EFFECT OF AEROFOILS 9
7 HOOD TAKE-OFF ANGLE FOR RECTANGULAR AND CIRCULAR
HOODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 AIR DISTRIBUTION FROM AN EXTRACTION POINT . . . . . . . . . . . . . . . . . . . . . 10
9 FORMULAE FOR DIFFERENT HOOD TYPES 11
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1 INTRODUCTION

Installation of Local Exhaust Ventilation (LEV) systems can be costly. Without proper
design they can fail to be effective either immediately or after fairly short periods of
time due to blockages etc.

Local exhaust ventilation should always be considered as a complete system, each

component being designed or selected as an integral part of the complete system.
The starting point should always be the extract hood to establish the location(s),
dimensions and extract volume required. Subsequently the ducting, air cleaner, fan
and stack can then be designed. A good understanding of the emission
characteristics and how exposures can occur should lead to the definition of the
control requirements and the specification of the hood design, extraction volume and
the overall extraction system design.

Ventilation may be required when a substance(s) escapes from a process or

otherwise becomes airborne and then results in a significant personal exposure
relative to Occupational Exposure Limits. Before turning to ventilation methods,
prevention or control of the emission at source should be considered. While
ventilation is normally concerned with airborne emissions, potential skin contact
should not be forgotten and, if appropriate, should be considered as part of the
overall control strategy. Where skin contact is regarded as a significant route, e.g.
with corrosives, skin allergens or material absorbed through the skin, emphasis
should be placed on containment and prevention of spillages etc. rather than just
relying on ventilation.

2 EMISSION CHARACTERISTICS

The physical airborne state (e.g. gas, vapour, fume, spray, mist, dust etc.) should be
known as it will dictate certain design features of the system. It is possible for
substances to be present in more than one state, for example dusts and vapour, or
liquids and vapour. It may also be possible for condensation of vapours to occur
either within the process or within the ventilation system. All these points should be
noted. The mechanisms by which the emissions become airborne should be
understood. These could be directly associated with the process or may be indirect
mechanisms associated with the operator or the environment.

Direct mechanisms could be due to, for example, pressure, agitation, displaced air or
kinetic energy. Indirect mechanisms could be, for example, opening lids or doors,
disposal of empty containers (particularly bags), emissions from spillages,
evaporation from stored containers or waste bins.

An understanding of the dispersion mechanisms should lead to an estimation of the

velocities involved. For example evaporation and diffusion results in very low
velocities, but this will be increased if the liquid is boiling due to both the thermal
currents and the expansion of the vapour. Velocities associated with welding will be
caused by both the thermal currents and the splatter.

Drum filling will produce emission velocities directly related to the air displacement
rate. These can be further increased if filling is external to the drum due to falling
velocity of the material, entrained airflows and impact velocities. Similarly emission
velocities from spraying are related to air/aerosol velocity, entrained air and the
impact and deflection when the aerosol strikes the booth wall. Although velocities
associated with grinding are predominantly due to the inertial velocities of the stone,
significant increase can be experienced due to entrained air along the side of the
stone.

Where the emission velocity is likely to vary during a process it will be necessary to
know the maximum velocity. This may not always be obvious, for example there
could be a high velocity of displaced air during the initial stages of drum filling due to
pressure build up in the feed lines during valve closure.

Emission velocities can either be calculated directly from process parameters or can
be estimated by observing or measuring emissions as they take place. Smoke can
be very useful here in both estimating velocities and indicating directions of
emissions. An estimation of the emission velocity will influence the selection of
required capture velocity.

Both environmental and process conditions can affect the emission or cause
secondary emissions, for example draughts or airjets from the process could increase
evaporation rates or produce dust clouds from powder spills (Fig 1).

The operator can also affect or cause the emission. For example, opening hatches,
walking past booths, discarding empty bags or sweeping up.

FIGURE 1 INFLUENCING FACTORS

External Process

Draughts, Traffic; Operator Displaced Pressure,

Compressed Air, Vehicles or movements Air Agitation,
Cooling fans Pedestrians Kinetic Energy

The process should be checked to determine if displaced air can cause or affect the
emission or possibly cause other problems (fig 2).

FIGURE 2 DISPLACED AIR

Within the Process External to the Process

Internal Migration Powders moving in Escapes

opposite direction
to displaced air

resulting in unexpected causing blockage or causing high

or remote emissions pressure build up velocity emissions

The process also should be checked to determine if there are any hot emissions or
any sources of heat that could affect the air movement around the emission.
3 CONTROL REQUIREMENTS

The characterisation of the emission should lead to an understanding of the control

requirements, for example, the number and location of the extraction hoods. It
should also be possible to specify the required capture velocity at the emission
sufficient to ensure adequate control (Fig 3 and Table 1).

FIGURE 3 CAPTURE VELOCITY

Too Low Velocity Required Velocity Too High Velocity

Results in
- exposures - Cost effective - excessive product entrainment
- workplace/operator control - increased external emissions
contamination - personnel discomfort
- accumulation - higher energy requirements

TABLE 1 EXAMPLES OF CAPTURE VELOCITIES REQUIRED FOR

DIFFERENT TYPES OF EMISSIONS

Condition of dispersion of Examples Capture

contaminant velocity
(m/s)
Released with practically no Evaporation from tanks, cold solvent 0.3 - 0.5
velocity into still air degreasing baths, etc.
Released at low velocity into Spray booths, drum filling within a 0.5 - 1.0
moderately still air booth, low speed conveyor transfer,
or welding
Active generation into zone of Spray painting in shallow booths, 1.0 - 2.5
rapid air motion drum filling without booth, conveyor
loading or crushers
Released at high initial velocity Grinding, abrasive blasting or 2.5 - 10.0
into zone of very rapid air tumbling
motion

Choice of capture velocity within recommended range will depend on local

circumstances governed by local air currents, toxicity of contaminants, emission
velocity.

4 DESIGN OF CAPTURE HOODS AND BOOTHS

Good design of the hood is essential for efficient contaminant control. It should be
designed to capture or contain the emission taking into account all the emission
characteristics and environmental factors. The term 'hood' is used to describe all
types of extraction devices; slots, rim ventilation, annular extraction, booths and
cabinets.
The most effective hoods are those which enclose or contain the emission. More air
is required as the level of containment decreases.
A good booth design is essential. A single point of extraction within a booth or
cabinet will result in poor air flow distribution. If this is off centre there will be
considerable turbulence resulting in recirculation of air within the booth. Emissions
may be brought to the face and could be redispersed by room air current. Poor
distribution within a booth or cabinet will also result in velocity gradients across the
face possibly leading to little or no velocity at points further from the extraction.
When combined with the recirculating currents this can result in loss of containment
(fig 4).

FIGURE 4 POOR VELOCITY DISTRIBUTION AND EXCESSIVE TURBULENCE

DUE TO A SINGLE POINT EXTRACTION

Even distribution of air flow within a booth or cabinet is important and can be
achieved by the use of perforated plenums (both input and extract where applicable)
or with baffles as in fume cupboards (fig 5).

FIGURE 5 EVEN DISTRIBUTION

Perforated plenum Back baffle

The booth design should take into account the effect of turbulence which can be
created by air movement. Edges of a booth or cabinet will cause turbulence in the
incoming air (fig 6). The containment will be significantly improved if the edges are
rounded or aerofoiled.
FIGURE 6 TURBULENCE AT EDGES AND THE EFFECT OF AEROFOILS

S t ra i g h t e d g e Rounded Edge Aerofoiled edge

For capture hoods, where the emission is not contained within the hood, it should be
positioned as close as possible to the emission without risk of excessive entrainment.
Air should always be drawn away from the operator's breathing zone.

Even distribution across rectangular or circular capture hoods is achieved by

minimising the turbulence in air on entry. To ensure smooth entry the hood take off
angle should be between 60° and 90° (fig 7). Even air distribution in slots is
controlled by pressure drop across the face. Satisfactory distribution can usually be
achieved if the face velocity is twice the plenum velocity.

FIGURE 7 HOOD TAKE-OFF ANGLE FOR RECTANGULAR AND CIRCULAR

HOODS

A number of examples of hood designs are shown in Appendix B.

5 EXTRACTION VOLUME

The extraction volume has to be sufficient to provide the required capture velocity at
the furthest point of required control. Where the emission is enclosed by the hood
the extraction volume should provide a face velocity across all the opening faces
sufficient to overcome the emission velocities. For capture hoods, where the
emission is not contained by the hood, the extraction volume required has to take into
account the rapid fall off in air velocity away from the extraction point (see fig 8). The
rate of fall off will be significantly reduced by adding a flange. In the case of circular
hoods the flange width should equal the hood diameter. For rectangular hoods the
flange width should equal the square root of the hood face area.

FIGURE 8 AIR DISTRIBUTION FROM AN EXTRACTION POINT

90° 60°

Maximum angle Minimum angle

 Air distribution from an extraction point

Air velocity at 1 duct diameter

d will be approximately
10% of the f ace velocity

1 0 0 60 3 0 15 7 . 5
Percentage of Face Velocity

Calculations to estimate the required extraction volume can be based on the required
capture velocity and the cross sectional area through which extracted air travels.
With booths and cabinets this is straight forward as the area of open face is used.
For capture hoods the surface area of the velocity contour at the furthest point of
required control is used. This is calculated using basic geometric formulae for
spheres and cylinders (see fig 9).

When a capture hood is rested on a flat surface the volume of air to achieve the
required capture velocity at distance X reduces compared with a free standing hood.
This required volume is calculated by assuming the hood is twice the size (as if it was
lying on a mirror). The volume calculated can then be halved.
FIGURE 9 FORMULAE FOR DIFFERENT HOOD TYPES

Type of Hood Criteria Formula for

Required Volume

PLAIN OPENING ASPECT RATIO < 5:1 Q = V(10X 2 + A)

FLANGED OPENING
ASPECT RATIO < 5:1 Q = 0.75 V(10X 2 + A)

PLAIN SLOT ASPECT RATIO > 5:1 Q = 3.7LVX

FLANGED SLOT ASPECT RATIO > 5:1 Q = 2.8LVX

CANOPY OVERHANG > 0.4D Q = 1.4PDV

EMISSION WITHIN Q = VWH

BOOTH
BOOTH

Q Volume flow rate (m3/s)

V Capture velocity (m/s)
X Distance between hood and emission (m)
L Hood length (m)
W Hood width (m)
H Hood height (m)
A Hood face area (m2)
P Perimeter of work area (m)
D Distance from work surface to hood face (m)
6 EXTRACTION SYSTEM DESIGN

The duct diameter is defined by the required duct velocity. This should be sufficient
to prevent the contaminant from settling within the duct. When handling any
particulate contaminant the required transport velocity should be between 17 and 25
m/s. Velocities used when handling gases or vapours are normally between 5 and 10
m/s.

The ducting should be designed to avoid any unnecessary duct resistance due to
poor bends, junction design and fan entry. These aspects are covered by ventilation
text books.

The selection of a suitable air cleaner, such as filter, cyclone, scrubber or carbon
absorption unit, is dependent on the nature of the contaminant. As stated earlier the
contaminant may appear in more than one physical state. The selection should also
consider environmental emissions. In most cases this will be a specialist matter and
reference should be made to ICI Engineering Technology specialists or the SPS Gas
Cleaning Manuals (see ref 10).

If the extracted air is partially or wholly re-cycled into the workplace the quality of
filtration and permissible concentration of contaminant returned should be carefully
considered. It should not normally exceed 10% of the Occupational Exposure limit.
This is a specialist matter and advice should be sought from ICI Engineering
Technology or Occupational Health.

The selection of the fan type and size should be based the extraction volume and
resistance of the system. The calculations required for fan selection can be found in
ventilation text books.

Stacks should not be adjacent to air inlets and should be as high as possible to clear
turbulence caused by the walls and roof of the building. Certain features, such as
chinaman's hats, may adversely affect dispersion. Specialist advice may be required
from ICI Engineering Technology.

7 SUMMARY

The ventilation system should be designed as a integral system starting with the
design of the hood based on the emission characteristics. Appendix A shows a
checklist that can be followed.
8 REFERENCES

Further ideas on design can be obtained from the following sources

1 Industrial Ventilation; A manual of recommended practice - American

Conference of Governmental Industrial Hygienists

2 Controlling Airborne Contaminants in the Workplace - British Occupational

Hygiene Society Technical Guide No 7

3 Local Exhaust Ventilation and the COSHH Regulations - ICI C&P

Occupational Health

4 Design, Use and Maintenance of Fume Cupboards - ICI C&P Occupational

Health

5 Dust and Fume Control No 1; Laminar Flow Booths - Engineering Design

Guide, ICI Engineering Technology

6 Design Guide for Laboratories, EDG.CIV.67.01 - ICI EngineeringTechnology

7 Integration of Special Purpose Centrifugal Fans in the Process,

EDS.MAC.01.24 - ICI Engineering Technology

8 Woods Practical Guide to Fan Engineering; B B Daly, Woods of Colchester

9 Plant and Process Ventilation; Hemeon, Industrial Press Inc.

10 Gas Cleaning, SPS; IC02874/9/90/2/B (Introductory Volume)

11 Laboratories - Design safety and project management, Edited by T J Komoly,

Ellis Horwood ISBN 0-13-521592-7
APPENDIX A LOCAL EXHAUST VENTILATION SYSTEM DESIGN CHECKLIST

A.1 CHARACTERISE THE EMISSION

Airborne or skin contact?

Physical airborne state; gas, vapour, fume, spray, mist, dust etc.?
Condensation of vapours or evaporation of solids or liquids?
Emission mechanisms; direct mechanisms and indirect mechanisms?
Emission velocities including maximum velocities?
Environmental and process conditions?
Operator related emissions?
Displaced Air?
Thermal currents?

A.2 CONTROL REQUIREMENTS

Number of hoods?
Location of Hoods?
Capture velocity?

A.3 DESIGN OF EXTRACTION HOOD

Enclose or contain the emission?

Hood Design; booths, cabinets, bench top, local extraction?

A.4 EXTRACTION SYSTEM DESIGN

Extraction Volume?
Transport velocity?
Duct diameter?
Duct layout; bends, branches, fan entry?
Air cleaner; filter, cyclone, scrubber, carbon absorption unit, other?
Extract air is partially or wholly re-cycled?
System resistance?
Fan size and type?
Stack?
APPENDIX B EXAMPLES OF HOOD DESIGN

LOCAL EXTRACTION Applications Advantages/Disadvantages

Slot Advantages
General
Simple device
Wide range of low velocity applications
Moveable
Localised fixed point emissions
Good all round access

Disadvantages
Welding Less efficient use of air
Control reach limited
No spillage control
Affected by cross draughts
Not for heat sources
Prone to operator misuse

Low volume high velocity General Advantages

High velocity or inertial emissions Compact
Low volumes
Can incorporate safety guarding
Specific
Grindstones Disadvantages
Circular saws May restrict access and visibility
Band saws Limited control area
Sanders Hood design critical
Polishers High energy extraction required

Rim ventilation Advantages

General
Good visiblilty
Low velocity emissions associated
Product not disturbed by airflow
with flat tables or open top
Simple and effective
containers

Disadvantages
Specific Control reach limited especially
Drum filling (limited to slow fill) in centre
Vapour degreasing High volumes may be required
Gluing table Not suited to coating baths due to
loss of control once item has
been lifted out of bath

Annular extraction General Advantages

Container filling Effective containment
Minimises entrainment
Minimal extract volume required
Specific
Drums Disadvantages
Big bags No control of spillages
Tankers Only part solution for container filling
Poor visibilty

Note
Drum emptying using ventilated lance
BEN CH TOP FACI LITIES Applications Adv antages/Disadv antages

Back draught General Advantages

Where control is required Reasonable control over wide area
over wide area Allows operator room to work

Specific Disadvantages
Laboratory bench Affected by eddy currents
Batching out small quantities Will not cover material spilling off
Low toxicity products bench
Not good with heat sources
Vulnerable to cross draughts

Down flow General Advantages

Bench or table top level functions Good control
Not affected by operator position
Specific Good all round access
Small batch preparations
Package emptying (up to 25 Kg) Disadvantages

Laboratory benches Not good with heat sources

Needs protecting from cross draughts

Ventilated box General Advantages

Bench top applications Reasonable control
Low toxicity materials Useful null point; balances not
affected, reduced entrainment
Specific
Weighing or handling of small quantities Disadvantages
Ventilated funnels or tundishes Cannot control material spillage off edge
Ventilated sinks Not good for heat sources
Affected by rapid operator movements

R EC EPT OR H OOD S

Canopy General Advantages

Hot, low velocity emissions Simple
Good control of hot emissions

Disadvantages
Inefficient use of air
High volumes usually required
Very poor control of ambient
temperature sources
CABI NETS Applications Advantages/Disadvantages

Down flow Gen eral Advantages

Bench top applications Good control
Use with high toxicity materials Little turbulence to disturb balance
Therefore good for sensitive balances
Specific OK for heat sources
Sampling
weighing Disadvantages
May restrict operation

Horizontal flow General Advantages

Bench top applications Reasonable control
Use with moderate/low
toxicity materials
Disadvantag es
Specific Affected by operator movements
Sampling
weighing

Specific Advantages
Fume cupboard
Laboratory work Maybe OK with heat sources

Disadvantages
Affected by operator position and
movement

Note
For best operator protection;
- head must not touch sash
- aerofoil fitted to base
- have sash below nose

Biological Specific Advantages

Microbial work Good control
Clean air work with toxic materials Operator and product protection
Not affected by operator position and
movement
 BOOTHS Applications Advantages/Disadvantages
Down flow General Advantages
Multiple operations over wide area Good control not much affected by
cross draughts, operator position or
Use with high toxicity materials
movements.
Specific Protects both operator and product
Batching operations
Gives spillage control
Package emptying
Self contained
Sampling
Provides own environment

Disadvantages
Not for use with heat sources
High cost & maintenance but justified
for toxic materials

Horizontal flow General Advantages

Reasonable control & protected from
Multiple operations over wide area cross draughts
Use with low toxicity materials Moderate cost
Gives spillage control

Specific Disadvantages
Batching operations Not for use with hot sources
Affected by operator position
Package emtying
and movement
Sampling
Notes
For best results operator must stand
sideways and not directly upstream
to emission source.
Greater protection can be obtained with
local extraction around emission
source.

Careful siting of make up air is

required for best results.

Local Horizontal Flow Specific Advantages

Controls spillages
Product discharge - container filling Entrainment minimised when used in
combination with inflatable seals

Disadvantages
Control limited oustide booth
Therefore prone to poor operator
practice - need for careful working.
Product Charging - container emptying