Spraying Systems Co. Pty Ltd
A.B.N 64 065 383 253
Improving Dust Management
from
Mine to Port
Presented By
Matthew Hayward
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 2 of 11
Ore Movement equals Dust
With the min...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 3 of 11
Water to control Dust
• Water is the ...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 4 of 11
How Dust Suppression works
• In order...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 5 of 11
Understanding Droplet Size
• High pre...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 6 of 11
Droplet Size
• Droplet size - VMD is ...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 7 of 11
Nozzle Maintenance
• Maintenance is u...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 8 of 11
New vs Worn Nozzle
• With nozzle wear...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 9 of 11
The Importance of Filtration
• Poor q...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 10 of 11
Belt Washing Stations
• Belt Washing...
Spraying Systems Co Pty Ltd
Improving Dust Management from Mine to Port Page 11 of 11
Common Problems from Mine to Port
• ...
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Matthew Hayward, Spraying Systems Co Pty Ltd - Improving dust management from pit to port

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Matthew Hayward, Senior Systems Sales Engineer (WA), Spraying Systems Co Pty Ltd delivered this presentation at the Mining the Pilbara 2013 conference. The conference aims to promote the sustainable development of mineral resources and the Pilbara region.

For more information, visit http://www.informa.com.au/miningthepilbara

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Transcript of "Matthew Hayward, Spraying Systems Co Pty Ltd - Improving dust management from pit to port"

  1. 1. Spraying Systems Co. Pty Ltd A.B.N 64 065 383 253 Improving Dust Management from Mine to Port Presented By Matthew Hayward
  2. 2. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 2 of 11 Ore Movement equals Dust With the mining process every movement of mined Ore generates dust. Below are twelve of the most common areas that created dust from ROM Bin to the Ship loader. ROM Bins Grizzly / Apron Feeders / Crushers Conveyors Transfer Chutes Screen Houses Stackers Stockpiles Reclaimers Train Load outs Ore Dumpers Belt Wash Stations Ship Loaders
  3. 3. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 3 of 11 Water to control Dust • Water is the one of the most effective options to control dust. • Water is the most economical solution rather than using Surfactants, Foam and Binders. • For water to be effective and maximise results it is a matter of the right setup. • A better understanding of Spray Technology by personnel will ensure the correct results are achieved using water. • Understanding droplet size and its importance to control airborne dust. Using Water to supress dust from an emptying Haul Pac into ROM Bin Understanding Dust Control • To maximise Dust management you need prevention and suppression. • Dust prevention uses water to make the dust particle heavier so that it cannot become airborne. • Dust Suppression uses water to capture airborne dust particles by combining – which becomes heavy and it falls down.
  4. 4. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 4 of 11 How Dust Suppression works • In order for dust suppression to work the droplet size has to be of approximate equal size to the dust particle size. • If droplet size is larger than dust particle all you achieve is turbulence. Understanding Nozzles Sprays • Air atomizing nozzles produce the smallest drop sizes followed by fine spray, hollow cone, flat fan and full cone nozzles. Air Atomizing Nozzle Fine Spray Nozzle Hollow Cone Nozzle Flat Fan Nozzle Full Cone Nozzle
  5. 5. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 5 of 11 Understanding Droplet Size • High pressures yield smaller drops and lower pressure yield larger drops. • Lower flow nozzles produce the smallest drops and higher flow nozzles produce the largest drops. Pressure and Flow Smaller Droplets Pressure and Flow Larger Droplets Drop Velocity • Drop velocity is dependent on drop size. Small drops may have higher initial velocity, but velocity diminishes quickly. Larger drops retain velocity and travel further. • Increases in surface tension increase drop size. • Hard Water – Calcium and Magnesium.
  6. 6. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 6 of 11 Droplet Size • Droplet size - VMD is the Volume Medium Diameter – Middle Range. • Droplets are 50% larger and 50% smaller. VMD 50% Smaller Drops 50% Larger Drops • New nozzles are ideal – correct droplet size, spray pattern, litre output at given pressure. • As nozzle wears – droplet size increases (more larger droplets than smaller), spray pattern distorts and output increases.  Droplet size  Angle  Output  Droplet size  Angle  Output
  7. 7. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 7 of 11 Nozzle Maintenance • Maintenance is usually low on priority list, on shutdowns the majority of maintenance repairs in done around the rest of the plant and not enough time is available for nozzle replacement. • Poor understanding of nozzle technology and detecting worn nozzles ensures no maintenance is performed by mine personnel. • Assumption that as long as water is still spraying there is no need for maintenance. • It’s important through visual detection to identify nozzles erosion, caking, corrosion and damage. Maintenance Timeline • 1 Day  24 Hours  1 Week  168 Hours  1 Month  672 Hours  2 Months  1344 Hours  3 Months  2013 Hours • Nozzle wear is not obvious • Excess water use • Minimal Dust Suppression • Replace nozzles 2-3 months New Nozzle Worn Nozzle
  8. 8. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 8 of 11 New vs Worn Nozzle • With nozzle wear for every 1% wear  5% additional volume output. • As volume output increases from the nozzle due to wear the fundamental factors of dust suppression/prevention such as, spray pattern, drop size, and coverage are compromised. Common Sprays Used in Mining Air Atomiser Nozzle Hydraulic Nozzle WhirlJet Nozzle VeeJet Nozzle FlatJet Nozzle FullJet Nozzle FogJet Nozzle SpiralJet Nozzle
  9. 9. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 9 of 11 The Importance of Filtration • Poor quality water blocks nozzles • Internal corrosion block nozzles • Nozzles wear quicker • Distorted spray patterns The right setup  Strainers should be placed by the pump and before the spray bar – in many original engineering designs strainers are placed in the circuit, though it is not taken into account the length of piping and long term corrosion effects. Pump Strainer Piping Strainer Spray Bar Dust Control, Cleaning and Ore Conditioning <= Ore Level Moisture • When determining all the sprays across the site they need to be calculated so the total water used does not exceed the maximum moisture level in the Ore. • Total allowable moisture • Starting moisture • Ore tonnage per hour • Recycled – re-screened Ore • Loss to evaporation • End moisture level <= All Site Sprays   Over wetting = Incorrect nozzles, calculations and worn nozzles
  10. 10. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 10 of 11 Belt Washing Stations • Belt Washing stations are part of process though can create dust which requires control especially at the end of conveyors where Ore flicks off creates dust. • Poor Belt Cleaning increases wear and tear to belts, rollers and bearings, increased vibration harmonics through conveyors and entire plant structure. • Sprays that are over wetting Ore will stick to the belts which in turn end up on conveyor belt assemblies.
  11. 11. Spraying Systems Co Pty Ltd Improving Dust Management from Mine to Port Page 11 of 11 Common Problems from Mine to Port • Common issues found from Mine to Port – Blocked nozzles – Missing nozzles – Wrong nozzles types – incorrect angles and capacity sizes – Poorly positioned sprays – Distorted spray patterns – Solenoids and test functionality not working – Water supply not available – Damaged spray bars – Damaged and leaking hoses – Poor Pressure – Poor water flow

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