Mason Trouchet, Rainstorm Dust Control - Action to Prevent Fugitive Dust

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Mason Trouchet, Technical Sales and Marketing Manager, Rainstorm Dust Control delivered this presentation at the 10th Annual Bulk Materials Handling conference 2013. This conference is an expert led forum on the engineering behind the latest expansions and upgrades of bulk materials facilities. It also evaluates the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information on this conference, please vist http://www.informa.com.au/bmh2014

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Mason Trouchet, Rainstorm Dust Control - Action to Prevent Fugitive Dust

  1. 1. Dust Control Materials Handling Week May 2013
  2. 2. Mine Site Dust Control One • Developing “Real time Dust Control Plans” • Conducting frequent audits to assess operating conditions relating to dust management plans.
  3. 3. Mine Site Dust Control Two • Real time dust monitoring
  4. 4. Mine Site Dust Control Three • Air quality modelling
  5. 5. Mine Site Dust Control Four • Utilising weather prediction and forecasting to prevent dust generation at source
  6. 6. Mine Site Dust Control METHODS OF DUST PREVENTION Objectives: Prevent dust from becoming fugitive in the first place. • Wet dust suppression using water. • Chemical dust suppression. Capture or drop fugitive dust from atmosphere • Mechanical dust suppression.
  7. 7. Mine Site Dust Control METHODS OF DUST PREVENTION Ventilation • Increase the airflow to dilute dust from environment Containment • Dust is trapped in a enclosure, filter system, negative pressure inside a building.
  8. 8. Mine Site Dust Control METHODS OF DUST PREVENTION Extraction and filtration • Airborne dust is extracted and filtered from the air Suppression • Water / additives
  9. 9. Mine Site Dust Control METHODS OF DUST PREVENTION Wind barriers and diffusers • Natural or artificial barriers placed in strategic positions to reduce velocity. Design • Plant, equipment and process to minimise dust generation. • Prevention of dust from becoming airborne in the first place is addressing the root cause and is the most critical aspect of good dust management.
  10. 10. Mine Site Dust Control METHODS OF DUST PREVENTION Objectives; Prevent dust from becoming fugitive in the first place. Abatement strategy. • Wet dust suppression using water. • Water is commonly used to control dust. Considerations of the cost benefit have changed over the past 5 years. • Water on dust control is water lost
  11. 11. Mine Site Dust Control METHODS OF DUST PREVENTION  Chemical dust suppression • Water absorbing • Wetting agents (water extender surfactants) • Foaming agents. • Binding / agglomerating agents • Veneer agents (crusting agents) • Petroleum based • Electrochemical • Polymer • Starch • Cellulose • Clay additives
  12. 12. Mine Site Dust Control Areas of concern: • Roads and trafficable areas. Single largest dust generation point • Open areas and stockpiles second largest dust generation point • Materials handling third largest dust generation point Objectives: • Prevent dust from becoming fugitive in the first place. • Capture or drop fugitive dust from atmosphere • Manage dust control programs • Environmental reporting and compliance
  13. 13. Mine Site Dust Control METHODS OF DUST PREVENTION • Water Considerations • Water quality • Ease of use and effectiveness to wet surface areas of substrate material. Advantages: • Sometimes easily obtained and inexpensive. • Feed equipment relatively inexpensive to install. • Good short term dust suppression, assuming the dust particles are contacted and wetted. • Normally readily available. • Agglomerates the surface particles. • Low environmental impact.
  14. 14. Mine Site Dust Control Disadvantages. • Water on dust control is water lost. Unsustainable practice - no water is recycled in dust control activity. • Dust control short term, ½ hour to 12 hours • Does not easily wet many substrates, resulting in inefficient dust control. • Improper use results in material handling problems, such as freezing, belt carry-back, crushing and screening hang-ups, throughput downtime loss. • Cost of water carts and the water. • Loss of water - Environmental impact • Volume of water, DEM moisture control. • Shipping moisture restrictions.
  15. 15. Mine Site Dust Control Roads and Trafficable Areas • Optimising water usage in dust suppression on haul roads, and exploring cost effective alternative options. • Roads and trafficable areas • Application tips and considerations. • Access roads. • Haul roads. • “Shandy Mixing” • Water cart / dust control teams and control.
  16. 16. Roads and Trafficable Areas Roads • • • • • • • • • Water carts Record the process. Manage and report Signage Application tips Flexible vs. Rigid Count the water Maintenance Costing rate / m2 / frequency / cost of product
  17. 17. Roads and Trafficable Areas Dustmag
  18. 18. Mine Site Dust Control  Chemical dust suppression • Water absorbing (deliquescent / hygroscopic) • Dustmag
  19. 19. Mine Site Dust Control  Chemical dust suppression • Water absorbing (deliquescent / hygroscopic) • Dustmag Attributes • Starts to absorb water from the air at relatively low humidity and high temperatures. • Suitable for underground. • Increasing surface tension between particles slows evaporation further tightening as drying progresses
  20. 20. Mine Site Dust Control  Chemical dust suppression • Water absorbing (deliquescent / hygroscopic) • Dustmag Attributes • Treated roads can be regraded and will self-heal under traffic with less concern for losing moisture and density. • Free rolling resistance results in less tyre damage. • More suitable in drier climates.
  21. 21. Roads and Trafficable Areas Dustmag
  22. 22. Roads and Trafficable Areas Dustmag
  23. 23. Roads and Trafficable Areas Dustmag
  24. 24. Roads and Trafficable Areas Dustmag
  25. 25. Roads and Trafficable Areas Dustmag
  26. 26. Roads and Trafficable Areas Dustmag • Count the water allocation Water Calculator Road Dust Suppresion Water m2 Water volume L Litres per m2 25000 62,500 2.5
  27. 27. Roads and Trafficable Areas Dustmag • Cost the water cart consider rate to area A) B) C) D) WATERCART COST WORKSHEET 12 WEEKS DUST SUPPRESSION BUDGET Number of Watercarts AVERAGE Watercart Cost per Hour Hours per Day Watercart Cost per Day = A x B x C E) F) G) Days of Use per Week Number of Weeks of Use TOTAL COST OF WATERCART(S) = D x E x F 1 $230 10 $2,300 7 12 $193,200 H) Length of Road (metres) I) Width of Road (metres) J) AREA OF ROAD (square metres) = H x I 8000 25 200000 K) L) M) N) $0.97 $0.900 $0.07 $13,182 TOTAL WATERCART COST PER SQUARE METRE = G / J COST OF DUSTMAG PER SQUARE METRE COST SAVINGS per Sq.M. OF DUSTMAG vs. WATERCARTS = K - L TOTAL COST SAVINGS OF DUSTMAG vs. WATERCARTS = M x J
  28. 28. Roads and Trafficable Areas Dustmag • Cost the water cart consider rate to area
  29. 29. Roads and Trafficable Areas Application tips • Evaluate what application program will fit with your workplace environment. • Top down surface application • Pavement mix. • Application frequency • Compaction • Road condition during application • Rain events
  30. 30. Mine Site Dust Control  Chemical dust suppression • Binding / Agglomerating agents • Polymers (PVA) Polyvinyl Acetate, Vinyl Acrylic Attributes • Agglomerates and binds the surface particles together, because of polymer adhesive properties. • Serves to water proof the road. • Can be used as Veneer coating for non-traffic and rehabilitation areas. • Versatile
  31. 31. Mine Site Dust Control  Chemical dust suppression • Binding / Agglomerating agents • Polymer (PVA) Polyvinyl Acetate, Vinyl Acrylic Limitations • Difficult to maintain hard surface. • Requires higher frequency top up for dust control than Dustmag. Application • Mixed into pavement and applied as a top coat. • 50% residual concentrate applied 1:10 with water. • Target rate 300 ml/ m2 concentrate for each 50mm depth. • Top coats mix 2 L/m2. Environmental Impact • None expected.
  32. 32. Roads and Trafficable Areas Polymag Dustmag Gluon • • • • • • • Top down surface application Pavement mix. Application frequency Compaction Road condition during application Rain event Maintenance to Rigid pavements
  33. 33. Roads and Trafficable Areas Polymag Paczyme
  34. 34. Roads and Trafficable Areas Polymag Paczyme Betta Wett
  35. 35. Mine Site Dust Control  Chemical dust suppression • Electrochemical Derivatives • Paczyme Organic Attributes • Agglomerates and binds the surface particles. • Changes characteristics of clay size particles. • Extends water penetration and efficiency, slows evaporation. • Increased MDD (Max Dry Density). • Organic suitable for use in sensitive environmental conditions. • Lowers permeability in expansive clay soils. • Reduced hydration cracking. • Concentrated format.
  36. 36. Mine Site Dust Control  Chemical dust suppression • Electrochemical Derivatives • Paczyme Organic Limitations • Performance dependent on fine clay mineralogy. • Needs to dry cure to set. • Difficult to maintain if full setting strength is achieved. • Limited life span. Application • Diluted with water between 1:500 to 1:1000 • 1L to treat 30m3. • Diluted to compaction agent.
  37. 37. Mine Site Dust Control  Chemical dust suppression • Electrochemical Derivatives • Paczyme Organic Origin • Enzymes, ionic products, sulphonated oils, ammonium chloride. Environmental Impact • Need specific product analysis. • Some products highly acidic in concentrated, undiluted form.
  38. 38. Mine Site Dust Control  Chemical dust suppression • Wetting agents (foams and water extenders) • Surfactants “Betta Wett” Attributes • Concentrated format. • Extends water penetration. • Slows evaporation, suitable additive to polymer applications. • Foaming formulations. Limitations • Limited life span.
  39. 39. Mine Site Dust Control  Chemical dust suppression • Wetting agents (foams and water extenders) • Surfactants, Nonionic, Anionic, Cationic. Application • Dosing spray systems for foam generation on belt feeds, 1:500 • Water extender 1:500 to 1:5000 Origin • Surfactant manufacturing synthetic. • Organic (palm oil) derivative
  40. 40. Open and Non Trafficable Areas Managing fugitive dust. Implementing control practices in open areas. Open areas and stock piles. Second largest dust generation source.
  41. 41. Open and Non Trafficable Areas Managing fugitive dust. Implementing control practices in open areas. Open areas and stock piles
  42. 42. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  43. 43. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  44. 44. Open and Non Trafficable Areas Open areas and stock piles • Veneering water waste example
  45. 45. Open and Non Trafficable Areas Open areas and stock piles • Port Kembla
  46. 46. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  47. 47. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  48. 48. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  49. 49. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  50. 50. Open and Non Trafficable Areas Open areas and stock piles • Veneering equipment
  51. 51. Open and Non Trafficable Areas Open areas and stock piles • Veneering
  52. 52. Materials Handling • • • • • • • • • Managing fugitive dust. DEM Dust Extinction Moisture. Managing water conditioning. Flow properties Crushing circuit Legal constraints shipping, and contract crushing. Additives Ion exchange Air Entrainment free falling materials
  53. 53. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  54. 54. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  55. 55. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  56. 56. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  57. 57. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  58. 58. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture • DEM under control
  59. 59. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture • DEM under control
  60. 60. Materials Handling • • • • • • • Managing fugitive dust. DEM Dust Extinction Moisture Injection opportunities Mechanical action In pit manual application or irrigation ROM water carts. Crusher plant
  61. 61. Materials Handling • Managing fugitive dust. • DEM Dust Extinction Moisture
  62. 62. Materials Handling • Managing fugitive dust. • Fog systems
  63. 63. Materials Handling • Managing fugitive dust. • Fog systems
  64. 64. Materials Handling • Managing fugitive dust. • Fog systems
  65. 65. Materials Handling • Managing fugitive dust. • Fog systems
  66. 66. Materials Handling • Managing fugitive dust. • Fog systems
  67. 67. Materials Handling • Managing fugitive dust. • Fog systems
  68. 68. Materials Handling Spray and Fogging Systems • Mist Curtain efficiency (droplet size and localized environmental considerations) • PSD and dust concentration, water to particle mass. • Inertia and Momentum of dust particles, wind velocity. • Nozzle, water quality, filtration, maintenance • Droplet Size distribution • Inertia and droplet momentum • Balancing of droplets with particle–air mix • Plant layout dimensions • Humidity
  69. 69. Materials Handling • • • • • • • • • • • Managing fugitive dust. Fog systems Design Water quality Build Install Commission, nozzle sizing Train, Maintenance. Parts Measure water flow Place fog close to dust generation point
  70. 70. Contractor Services Contractor services • How much service will depend on the dust management team? • On site application and equipment • Separation of application services, product supply and environmental monitoring. • Gearing up the local contactors • Recording abatement strategy's. • Worksheet samples • Area mapping • Equipment design and installation
  71. 71. Contractor Services MINING COMPANY ABC A.B.N. *********** Minutes of Meeting Mining area XYZ Dust Management Held 04-Dec-12 ATTENDANCE Attendance Julia Gillard (0429388388) Tony Abbott Wayne Swan Sarah Hanson young Mason Trouchet Bob Carr Mine Contractor Mine Enviro Rainstorm Mine Present Present Present Absent Present Absent Mason Trouchet Joe Hocking Malcom Turnbill Craig Thomson Peter Slipper Rainstorm Contactor Contactor Contactor Vistor Present Present Absent Apology Apology File located at : OBJECTIVE: To review current conditions and plan dust controls for coming week
  72. 72. Contractor Services OBJECTIVE: To review current conditions and plan dust controls for coming week 1. Dust Control Inventory Item Min Stock Water (John) Max Stock 3,000-l Surfactant 30-l Road suppresant 23000l required No Action 3500 required No Action 3,100-l Mulch 300-m3 Hydromulch Rainstorm suppresant Gluon Current Action Stock 50000L delivery due today 30-l No Action 500 250-m3 5 hectacres 3 hectacr required due delivery today Today 2. Equipment Availability Equipment Condition Dust Suppression Sprinklers Total No of Sprinklers 374 Total Sprinklers Available 230 61% TEOM ALARMS TDC Healthy TDC Healthy Contractor Equipment Water cart an issue last week new truck due Wednesday -- still issue with pump v/v Mulcher - Side Spreading Tractor Okay Rainstrom Okay 4. Weather Trends 4-Dec 5-Dec Tue Wed moderate moderate 26 27 south westerly to 35kl/hr southerly to 30k/h 6-Dec 7-Dec 8-Dec Thu Fri Sat moderate high moderat 32 hot south westerly westerly southerl to 30k/h to y to Mining CO Custom Web Site (logon & password required) Bureau of Meteorology
  73. 73. Contractor Services 5. Dust Management Scope New and ongoing items. Item Location Priority 19 TSF 3 – sprinkler HIGH system Who Tony Abbot 35 TSF 4 south wall MEDIUM Wayne S 45 Batters on south side of TSF 1 MEDIUM Slipper 52 exposed sand 67 TSF 2 sth east 68 back drain MEDIUM Craig Thomson MEDIUM MEDIUM Julia 70 TSF 2 west wall HIGH 71 Waste disposal area HIGH 72 TSF3 east HIGH Malcom T 79 road from TSF 2 to HIGH TSF 3 82 header roads TSF MEDIUM Tony Abbot 2 & TSF 4 83 TFS 2 exposed MEDIUM Rainstorm beach area 90 TSF 6 excavator track 91 TSF 2 MEDIUM 92 TSF 2 93 TSF 4 HIGH HIGH HIGH Comment progress Extend sprinklers -now have 2 broken in Dozer not available east ==pumping eccess and will need to off maintain moisture Mulch small patch up job to do change to new header - planned for 2 weeks waiting on time instrumentation funds investigate if Rainstorm trial to start in 1 have a product for sand month dust suppressionarea Gluon disturbed excavate to turn ready to clear ongoing tidy and cover area disturbed by Rainstorm 80% comp Consult with processing Julia to set up meeting with stakeholders within the plant ABC required to fix capped sprinkler in emergency dump area grade and treat Rainstorm to investigate mulch sides and over headers start this week cover as much as possible with mag west end done -- east cement bank to do Dustmag mulch areas either end of dyke and top of TSF east wall 50% done Gluon sand outlet ongoing Dustmag access road on south side
  74. 74. Contractor Services New Business Wayne to contact Morris Turnbull in regard to improved monitoring opportunities. Peter Slipper has requested to be involved with this contact and will set a date. The attached survey of the exposed area shows an increase to 5 hectacres due to exposed areas on the stockpile at TSF 7. Geo now developing a set of harrows to increase dryiing. TSF 2 N/W corner where retic pipe being stacked -requires adequate warning to traffic -- I/H today Treatment Class Description 1 Water sprays 2 Dustmag Application Rate As required 1.5 L / m2 Mulch applied at 300- 3 Mulch, Seeding, 4 m3 /hectare (25mm thk layer) Hrydromulch applied at 1,000-t/hectare (14mm thk layer) Flooding ROAD Water , repair shandy mix Dustmag tip road References: Document NumberDescription 5814 Aggregate/ Mulch Spreading for Dust Control 62754 Dust Suppression using Sprinklers 38101 Spray Gluon For Dust Control 38065 Establishing Pasture for Dust Control 5817 Use of Dustmag as a Dust Suppressant 40584 Waste Oil Collection and Testing Procedure 5813 Maintain Mobile Irrigation Systems 38063 Dust Control Management Planning 69568 Manage Dust During Construction at Residue 56931 Residue Dust Emission Control Strategy 69584 TEOM Alarm Procedure 58016 Response to Dust Risk Rating 5816 Weekly Area Inspections and Meetings 3450 Ambient Dust Monitoring Information (4,500-l Waste Oil + 10,000-l Water + 40-l) at 10,000-l/hectare ie 3,100-l Dustmag and 28-l per hectare
  75. 75. Contractor Services
  76. 76. Mine Site Dust Control Feed batching equipment: • Automated
  77. 77. Mine Site Dust Control Feed batching equipment: • Manual batching
  78. 78. Mine Site Dust Control Feed batching equipment: • Mobile
  79. 79. Mine Site Dust Control Feed batching equipment: • Mobile
  80. 80. Mine Site Dust Control Feed batching equipment: • Mobile
  81. 81. Mine Site Dust Control Feed batching equipment: • Fixed
  82. 82. Mine Site Dust Control Feed batching equipment: • Fixed
  83. 83. Mine Site Dust Control Feed batching equipment: • Fixed
  84. 84. Contractor Services Contractor services • Skill set to apply products. • In house vs out sourced. • Road application skill set • Veneer application skill set • Tools of the trade
  85. 85. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding • • • • • • • • Fibres Binders Seeds Fertiliser Top Soils Surface Preparation Machinery Logistics
  86. 86. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  87. 87. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  88. 88. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  89. 89. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  90. 90. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  91. 91. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  92. 92. Rehabilitation and Hydroseeding Veneering Rehabilitation. Hydro Mulch Hydro Seeding
  93. 93. Mine Site Dust Control • Blasting
  94. 94. Mine Site Dust Control • Blasting
  95. 95. Mine Site Dust Control • References • • • US Department of Agriculture Forrest Service Technology program Transport system Watershed and air management November 1999 US Army corps “Effectiveness of dust control agents applied to tank trails and helicopter landing zones” Benefits of chemical dust control technologies, D Casey Roe University of Wollongong P Wypych 2012 workshop. • • www.rainstorm.com.au www.sunhawk.com.au • Mason@rainstorm.com.au •

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