11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
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Peter Wypych, University of Wollongong, Modification of Existing Plant to achieve Effective Dust Control and Suppression

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Peter Wypych delivered the presentation at 2014 Bulk Materials Handling Conference.

The 11th annual Bulk Materials Handling Conference is an expert led forum focusing on the engineering behind the latest expansions and upgrades of bulk materials facilities. This conference will evaluate the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information about the event, please visit: http://www.informa.com.au/bulkmaterials14

Published in: Engineering, Business, Technology
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Peter Wypych, University of Wollongong, Modification of Existing Plant to achieve Effective Dust Control and Suppression

  1. 1. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 1 Modification of Plant to achieve Effective Dust Control and Suppression Peter Wypych wypych@uow.edu.au The 10 Ways to Control Dust 1. General Ventilation (dilution) 2. Containment (integral filtration) 3. "Push–Pull" System 4. Suppression (water, chemicals, additives, foam): Total Particle or Veneer Treatment 5. Mist/Dry Fogging Systems: PSD/droplet size 6. Agglomeration (ionisation, ultrasonics) 7. Local Exhaust Ventilation  Vacuum PC 8. Wind Barriers (trees) 9. Vegetation Protection 10.“Prevention”  Dust Generation Mechanisms (solids/air flows; particle damage; etc)
  2. 2. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 2  Dustiness/Dust Extinction Moisture (DEM):  AS4156.6 (2000)  I.S. EN15051 (2006)  Veneer Treatment… New Developments in Sustainable Dust Suppression Technology Video2  Total Treatment  Bulk Characterisation:  Chemical Composition  Wettability  Moisture retention (evaporation)  Agglomeration  Flowability (handleability)  …to meet Application Requirements  …including Environment & Social Impacts Video1 BMEA Rotating Drum Dustiness Testers I.S. EN15051AS4156.6
  3. 3. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 3 Comparison of Dustiness Tests  System Effect  Standardisation Dustiness Test Issues Ore at 8.1% wb (DEM = 11% wb) Conc at 1.6% wb (DEM = 2.8% wb) …Possible Handling/Flow Problems!!
  4. 4. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 4 Mist/Dry Fogging Systems – Issues: 1. Mist Curtain Efficiency (depends on product and application requirements)… 2. PSD and Dust Concentration 3. Droplet Size Distribution (DSD) 4. Nozzle Design (air-water; water; impurities) 5. Inertia and Momentum of Dust Particles and Air (including “gusts”) 6. Inertia and Momentum of Droplets 7. Dynamic “Balancing” of Droplets with Particle-Air Mixture 8. Orientation (plant layout; dimensions) 9. External Factors (obstructions; peak flows) ROM Hopper Dust Emission Video
  5. 5. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 5 Stacker Dust Emission Video Ref: Enviromist Nozzle Design (air-water)
  6. 6. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 6 ROM Hopper Conveyor Transfer Case Studies Ref: Enviromist Ref: Enviromist Ref: Enviromist CHPP Conveyor Transfer (new H2O high-energy dry-fogging nozzles)
  7. 7. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 7 Video1 Video2 Video3 Underground Coal Mine Video4 Underground Coal Mine – Longwall Video
  8. 8. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 8 Many “Fugitive” Dust Emissions occur during Free-Falling Streams of Bulk Material: Prevention: (1) Dust Generation and Air Entrainment Mechanisms  Main Sources of “Fugitive” Emission?? Air Entrainment and Dust Generation Research
  9. 9. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 9 Air Flow in Bulk Material Stream Double h  220% increase Double h  60% increase  Exp/New Theory Q  h5/3:  CEMA Model Q  h2/3: Other Case Studies (free-falling materials) StackerROM Hopper Ship Loader Conveyor Transfer 2Conveyor Transfer 1 Car Dumper 1b PSD & DSDCar Dumper 1a Car Dumper 2a Car Dumper 2b Success !! New Dry Fog Spray Bars Car Dumper 1c
  10. 10. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 10 Dust “Lift-Off” Characteristics Dust “Lift-Off” of Coarse Magnetite Video1 Video2 Dust “Lift-Off” of Concentrate  Max Belt Speed Transfer Station Case Study More Case Studies
  11. 11. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 11 P1 P2 6 m/s Chute P = P2 – P1 Ref: Wypych, 1995 Problem Quantification Rubber CurtainsPlenum Ref: Wypych, 1995 Solution (filter/LEV not possible)
  12. 12. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 12 Video3 Video1 Video4 Crushing Station Video2  Surges and/or Peak Product Flows (Velocity Variations)  Minimise Air/Dust “Surges”  Unnecessary Impacts, Wear & Dust Generation Prevention: (2) Improved Solids-Air Flow Prediction/Control  To Minimise/Avoid: e.g. Conveyor Transfer Validated DEM Design Paper
  13. 13. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 13 Case Study: Iron Ore Wagon Loading & Discharge  Aim: Investigate operational problems with current Iron Ore Wagons and develop options to solve various problems… 1. Unreliable/unpredictable loading (fines; dust) 2. Slow discharge  Demurrage costs 3. Incomplete discharge  Overloading wagons  Exacerbates flow and dust problems 4. Dust emissions: spillage; dust lift-off; unloading; residual ore; collapsing ratholes Video Root Causes  Fines, TLO Hopper  Funnel-Flow  Ratholes  Collapsed  Ore Fluidised Problem 1 – Train Loadout
  14. 14. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 14 Fluidisation of Iron Ore Vmf = Minimum Fluidisation Velocity Deaeration of Iron Ore Normalised Deaeration Time Constant + FP  TLO Hopper Re-Designed: Mass-Flow (allow deaeration; avoid collapsing ratholes) …Identifying/Solving Root Cause!! Problems 2, 3 and 4  FP (Max Strength)  New Wagon Design  Full-Scale Trials (prototype)…
  15. 15. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 15 100% Discharge < 20 sec!! …Identifying/Solving Root Cause!! Thanks to Flow Properties!!

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