Documente Academic
Documente Profesional
Documente Cultură
Type
Road
Material
Transfer
Surface
Binding
CT-9030
Surfactant
Yes
Yes
No
CT-936
Surfactant
Yes
Yes
No
Ct-9040
Foam Agent
No
Yes
No
CT-9054
Ligno
Yes
Yes
Yes
CT-9054S
Ligno/Surfact
Yes
Yes
Yes
CT-9064
Organic Polymer
Yes
Yes
Yes
CT-904X
Residual Foam
No
Yes
No
CT-907X
Humectant
Yes
No
No
CT-908X
Tar Emulsion
Yes
No
No
DUST
Dust is defined by the Mine Safety and Health Administration as finely divided solids
that may become airborne from the original state without any chemical or physical
change other than fracture.
These fracturing processes include crushing, grinding, impact, abrasion, transfer
operations, loading, dumping, driving over materials, wind erosion, etc. Anytime
materials are handled dust is generated in varying amounts.
While dust generation is unavoidable in many material processing operations, it must be
controlled to reduce health hazards, reduce equipment damage, improve visibility, for
community relations aspects and to meet government regulations.
Surrounding neighbors can attract great attention to their cause of reducing airborne dust
Even to the point of getting the local media involved, which is a sure sign, the government
inspectors and regulators will follow.
DUST CONTROL
Dust control technology involves designing a system specifically for a particular dust
problem. A dust control system will consist of one or more of the following:
Containment this is the first step in controlling dust because of the need to control
the material stream and the associated air movements before dust control can be
successful.
Containment involves adding or rebuilding chutes, chutewalls,
wearliners, sealing systems, entrance and exit treatments, etc.
Another form of containment used to reduce wind velocities in open areas to prevent
re-entrainment of dust and to aid in the effectiveness of dust suppression
are Wind fences.
SUPPRESSION
Plain water was the first type of dust suppression method. This method of wet suppression was
improved through better spray nozzle technology, which enhanced the dust capture. While usually the
least costly at initial installation, it is also the least effective in controlling many types of dust.
Some material cannot tolerate large amounts of water. Fly ash and cement will set up if water is added.
Coal dust will simply float on the surface of water without actually being wetted. Fuels such as coal,
wood, trash and hog fuel incur large BTU penalties when large amounts of water are added. Plain
water can also be considered to be point specific. When the water evaporates, the dust control ends.
Water/surfactant used mostly in truck, railcar dumps and road-spraying trucks, water/surfactant
consists of water and a surfactant chemical being sprayed onto a material or into the air to capture
airborne dust or prevent dust from becoming airborne. Next to the fire hose (plain water) technology
this adds the most water to a given material. (A surfactant is any chemical that alters waters properties
to improve its wetting abilities.) Water/surfactant mixes can be considered to be residual in that they
will provide some dust control at points farther along the material stream flow.
Foam
Water reduction can be of great value when dealing with materials that cannot tolerate
large volumes of water. Chute pluggage, freezing problems and BTU penalties are all
reduced.
In addition, foam also offers a residual benefit.
Fog is formed by pressurizing plain water and forcing it through nozzles that atomize
the droplets. The smaller the droplets, the better chance they have of contacting and
capturing dust particles. Fog adds the least amount of water but is the most sensitive to air
movements since the droplets are small enough to be blown out of the treatment area. Fog
is also point specific in there is no carry over to the next dust generation location.
Which system to use and where to apply it are based upon factors such as the materials
tolerance to moisture addition, water sources close to the application points, physical size
of the area to be treated, temperature of the material generating the dust, climatic
conditions, prevailing winds, treated tonnages, material reduction and handling sequences,
etc. Many factors must be taken into account when designing a dust control system for a
specific operation. Changing materials, material specs, belt loadings, belt speeds, or other
operating parameters will change the dust control requirements. These factors must also be
taken into account.
DUST COLLECTION
Collection is now commonly used in conjunction with suppression or in some areas as a
standalone technology.
Dust collection systems capture airborne dust from the source either by filtering the air in
the area of the dust generating mechanism (insertable collectors) or by transporting dustladen air to a central location of filtering/cleaning (baghouse or central collectors).
Insertable collectors allow air to pass through fabric filter elements to remove dust from
the air. The filtered dust is allowed to agglomerate or cake to the filter elements until the
particle clumps are heavy enough to be dislodged and dropped directly back into the
material stream without the use of transport ducting, ancillary equipment or the problems
of disposing the collected dust.
Plant Managers
Production Managers
Safety Directors
Maintenance Managers
Employees
Neighbors
What is Dust?
Finely divided solids that may become airborne from their original state
without any chemical or physical change other than fracture
Individual dust particles are measured
in microns.
Ten thousand microns equal one
centimeter, or 0.3937 inch.
EPA classifies particulate matter in two
sizes.
Particles smaller than 2.5 microns are
referred to as PM2.5.
Larger particles up to 10 microns in
diameter are designated PM10.
The PM10 classification includes most
types of fugitive dust
Sources of Dust
Material Impact
Crushing
Screening
Conveying
Stockpiling
Reclaiming
Loading
Transporting
Vehicle traffic
Wind
Suppression
Definition of Treatment
Continuous
Treatment
24 hours/day
Short Term
(Hours)
Medium Term
(Days)
Long Term
(Weeks)
Watering
Surfactants
Emulsions
Tar
Latex
Petro
Chlorides
DOSS
Lignins
Magnesium
Calcium
Sodium
Humectants
Organic Polymers
Nalco
additive: Water
/: WaterRatio
Ratio
Surfactant
Water Surface
Tension
Typical
water
Distilled
water
1 : 2000
1 : 4000
1 : 6000
1 : 8000
1 : 10,000
Dynes/cm2
72.5
70.0
33.4
34.7
36.1
37.4
39.3
Newton/m2
0.072
0.07
0.030
0.035
0.036
0.037
0.039
Drivers
Fuel
Maintenance/parts
Corrosion
Water
Water rights
Adequate supply
Pumping costs
Pressurized Spraying
Residual dust control
treatment
Agenda
Pressurized
Spray bar
Surface Preparation
Surface Preparation
Surface Preparation
Before
After
Application Examples
Extended Residual Programs
Case A.
Initial application: 70% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 2 weeks after initial application, light spray with
water only to keep the product activated.
5 weeks after initial application: Re-apply at a 30% solution.
8-9 weeks after initial application: Re-apply at the initial application rate.
Case B.
Initial application: 60% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 8 - 10 days after initial application, light spray with
water only to keep the product activated.
5-6 weeks after initial application: Re-apply at a 60% solution.
Case C.
Initial application: 50% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 10 days after the initial application, light spray with
water only to keep the product activated.
Every 4-5 weeks after initial application: Re-apply at a 50% solution.
Chemistry
Tangible
FREQUENCY
SAFETY
ENVIRONMENT
EZ of
CLEANUP
OTHER
Multi/day
X-tra Traffic
Wet/slippery
Yes
Muddy,
Morale
Oils/Tar Emul
7-14 days
Slippery
Run-off (PAHs)
No,
Morale
Oil base,
None
Renewable
Ca/MgCl2
30-45 days *
Toxic
Yes
Highly
Corrosive!
Humectant &
Organic Poly
30-60 days *
Bio-degrades
Yes
Renewable
Resource
Water
EPA Requirements
EPA Requirements
ADR Dust
Monitoring
System
Dust particles that measure 10 microns or less in diameter. These dust particles can be
inhaled into the respiratory system and become lodged in the lungs. Depending on the type
of dust, prolonged exposure to respirable dust can cause fatal respiratory illnesses such as
Black Lung and Silicosis.
Total Dust
All dust particles regardless of size. Regulation of total dust is typically required when the
dust is considered to be a nuisance and less of a health hazard, i.e., limestone dust in a rock
quarry.
Fugitive Dust
The particulate that is captured in the atmosphere that does not allow itself to fall to the
earth of its own weight.
Static
Pressure
A force that expands or compresses the air in a chuted area. This pressure will cause dust to
be forced out of the transfer chute, through leaking skirtboard seals or tail box assemblies.
This type of pressure can be positive or negative.
Velocity
Pressure
A force causing a volume of air to accelerate from rest to a particular velocity. Air
velocities create airborne dust and are always positive.
Capture
Velocity
Air velocity required to overcome opposing air currents for the purpose of capturing
airborne dust.
Carrying
Velocities
Air velocity required to suspend a dust particle. Bulk density and particle size determine
this required velocity.
Terminal
Velocity
Maximum attainable speed while falling through the atmosphere subject to the gravitational
pull of the earth and not taking into consideration any velocity associated to the material
transfer.
Silicosis
This is an irreversible lung disease caused by inhaling silica dust particles. As dust particles
become lodged in the lungs, scarring of the lung tissue occurs, resulting in shortness of
breath.
Black Lung
This is an irreversible lung disease caused by inhaling coal dust particles. As dust particles
become lodged in the lungs, scarring of the lung tissue occurs, resulting in shortness of
breath.
Induced Air
Collected by the moving products as it leaves the head pulley of the conveyor.
Pitot Tube
A device used in conjunction with a manometer to measure static pressure and total pressure
in a collection duct or transfer chute.
Threshold
Limit Value
(TLV)
Dust concentration standard required by the Mine Safety and Health Administration,
measured in mg of dust per M3 of air. Each bulk material has a specific TLV.
Permissible
Exposure
Limit (PEL)
Dust concentration standard required by the Occupational Safety and Health Administration,
measured in mg of dust per M3 of air. Each bulk material has a specific PEL.
Time-Weighted Dust standards as set of OSHA and MSHA are measured over an 8-hour time-weighted
average.
Average
PM10
Point Source
Solution
This is a dust control solution that controls the dust only at the point of application. Examples
of this include dust collection and fog dust suppression technology. These technologies may
be required at each dust emission source where they treat the dust-laden air.
Residual
Effect
Solution
This dust control solution can be applied at one dust source and provide residual dust control
at several possible dust sources after initial application. Examples of this include foam dust
suppression and water/surfactant dust suppression. These technologies actually treat the
dust-laden material before the dust becomes airborne.
Agglomeration Dust particles collide with water droplets and other dust particles or material, sticking
together and increasing in mass. The increased mass forces the agglomerates to fall from
the air and return to the main material flow, or stay with the main material flow, depending
on when the agglomeration occurs.
Suppression
The ability to suppress or not allow something to happen by the use of a method or piece of
equipment.
Foam Dust
Suppression
This is a residual effect solution that combines a solution of water and surfactant along with
compressed air to expand the surface area of the solution to capture dust. This foam is then
mixed with the material for the purpose of agglomerating the fine dust particles with the
main material flow. This technology can add between 0.1% and 0.4% moisture addition by
weight.
Water/Surfact
Dust
Suppression
This is a residual effect solution which combines a solution of water and surfactant to make
the water wetter and allow agglomeration to occur between the water droplets and the dust
particles. This solution is then mixed with the material for the purpose of agglomerating the
fine dust particles with the main material flow. This technology can add between 0.4% and
2.5% moisture addition by weight.
Surfactant
A chemical that is added with water to alter its surface tension. This allows the water to
adhere to bulk material to promote agglomeration. Many materials are not water friendly
and will not agglomerate with water unless surfactant is used. For example: if you wash
your hands with soap, they will be much cleaner than if you only washed them with water.
The soap acts as the surfactant.
Tackafier
This is an additive added to water that adheres to bulk material to give it long-term residual
dust control, even after the water evaporates. This can be used in rail cars to minimize
windblown dust loss, or to live storage piles.
Crusting
Agent
This is an additive added to water and is sprayed onto dead storage piles to reduce oxidation
and break down bulk materials. This seals the top layer of an undisturbed dead storage pile,
minimizing windblown dust emissions.
Fog Dust
Suppression
This is a point source solution that applies small water droplets into the airflow. These
water droplets are similar in size to the dust particles, which promote agglomeration
between the dust particles and water droplets. This technology can add between 0.1% and
0.5% moisture addition by weight.
This is a point source solution that filters dust-laden air at the source. Agglomeration of the
Insertable
Dust Collector dust occurs on the collection bags, forming a filter cake, and returning the agglomerated dust
particles to the main material stream.
Central Bag
House Dust
Collector
This is a point source solution that filters dust-laden air through a centralized location by
transporting the air through dust collection ducts. The collected dust is then processed
through agglomeration by adding water or binding agents. This agglomerated material is
then either reintroduced into the material handling process or is disposed of, depending on
the specific material and process. This technology provides 90% plus efficiency of
collection.
Central
Mechanical
Dust Collector
Dust is collected and transported to a central location. When the dust reaches the collector
cyclone, the weight of the dust allows the particles to settle out into a hopper. The material
is then either reintroduced into the material handling process or is disposed of, depending on
the specific material process. This technology provides 60% plus efficiency of collection.
Personal Dust OSHA and MSHA require that employers perform periodic personal dust sampling. This is
done by using a filter cassette assembly, cyclone, and personal sampling pump. This test is
Sampling
completed over an 8-hour time-weighted average.
BTU Penalty
This is a factor to be considered whenever a thermal process is being used, i.e., coal is being
burned for fuel, clay is being dried for the manufacture of cement, etc. A BTU is a British
Thermal Unit. All fuels have a specific BTU rating. When moisture is evaporated from the
material in the process of burning the fuel or drying the material, it requires energy to
evaporate that moisture. This lost energy is termed as the BTU Penalty and can be
calculated in terms of dollars.
Compression
Material laying on a conveyor belt with its cross sectional area being as dense as it will ever
be with the given material size as opposed to free-fall.
Bulk Density
Inherent
Moisture
The amount of moisture that is atomically bound inside the individual material particles.
Surface
Moisture
The amount of moisture that is externally added to material flow and can run off of the
material.
Flashing of
Chemical
The ability of chemical to turn to steam or evaporate with temperature leaving the
suppression of little or no effect (generally 190-220F).