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BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Dust Solution Options for the
Handlin...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

New Developments in Sustainable
Dust ...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Comparison of Dustiness Tests

© Wypy...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Mist/Dry Fogging Systems – Issues:
1....
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Stacker Sprays - Ineffective

Video

...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Control Volume, Q ?
> Interstitial
+ ...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Air Flow in Plume

 CEMA Model Q  h...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Case Studies

© Wypych, 2013

Problem...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Solution (filter/LEV not possible)

P...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

PREVENTION: (2) Improved Solids-Air F...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Bulk Material Calibration for DEM
(pa...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Large-Scale “Dynamic” Validation
Conv...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Validated DEM of Impact Plate CT

 P...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Case Study: 5000tph Ship Loader
Dry

...
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong

Case Study:
Iron Ore Wagon Loading & ...
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Peter Wypych, University of Wollongong - Dust Solution Options for the Handling, Loading and Transfer of Bulk Materials

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Peter Wypych, General Manager, BMEA, University of Wollongong 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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Transcript of "Peter Wypych, University of Wollongong - Dust Solution Options for the Handling, Loading and Transfer of Bulk Materials"

  1. 1. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Dust Solution Options for the Handling, Loading & Transfer of Bulk Materials Peter Wypych wypych@uow.edu.au The 10 Ways to Control Dust 1. 2. 3. 4. General Ventilation (dilution) Protection Containment (integral filtration) "Push–Pull" System 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 10.“Prevention”  Dust Generation Mechanisms (solids/air flows; particle damage; etc) © Wypych, 2013 4 June 2013 1
  2. 2. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong New Developments in Sustainable Dust Suppression Technology  Dustiness/Dust Extinction Moisture (DEM):  AS4156.6 (2000)  I.S. EN15051 (2006)  Particle/Bulk Characterisation:      Chemical Composition Wettability Moisture retention (evaporation) Agglomeration Flowability (handleability)  …to meet Application Requirements  …including Environment & Social Impacts © Wypych, 2013 BMEA Rotating Drum Dustiness Testers I.S. EN15051 AS4156.6 © Wypych, 2013 4 June 2013 2
  3. 3. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Comparison of Dustiness Tests © Wypych, 2013 Dustiness Test Problems Ore at 8.1% wb (DEM = 11% wb) Conc at 1.6% wb (DEM = 2.8% wb) …Possible Handling/Flow Problems!! © Wypych, 2013 4 June 2013 3
  4. 4. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Mist/Dry Fogging Systems – Issues: 1. Mist Curtain Efficiency (depends on product and application requirements)… 2. PSD and Dust Concentration 3. Inertia and Momentum of Dust Particles and Air (including “gusts”) 4. Nozzle Design (water; air-water; impurities) 5. Droplet Size Distribution 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) © Wypych, 2013 ROM Hopper Sprays - Ineffective Video © Wypych, 2013 4 June 2013 4
  5. 5. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Stacker Sprays - Ineffective Video Solutions  Workshop D © Wypych, 2013 PREVENTION: (1) Dust Generation and Air Entrainment Mechanisms Many dust generation processes involve free-falling materials:  “Fugitive” Dust Particles © Wypych, 2013 4 June 2013 5
  6. 6. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Control Volume, Q ? > Interstitial + Induced + Entrained + Displaced Entrained Air  Dominant!! © Wypych, 2013 Air Entrainment and Dust Generation Research © Wypych, 2013 4 June 2013 6
  7. 7. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Air Flow in Plume  CEMA Model Q  h2/3: Double h  60% increase  Exp/New Theory Q  h5/3: Double h  220% increase © Wypych, 2013 Other Case Studies (free-falling materials) Truck Dump Train Dump Stacker Loader ROM Hopper Rotary Car Dumper 1 Rotary Car Dumper 2 ….Other Examples  Workshop D © Wypych, 2013 4 June 2013 7
  8. 8. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Case Studies © Wypych, 2013 Problem Quantification P1 Chute P = P2 – P1 P2 6 m/s Ref: Wypych, 1995 © Wypych, 2013 4 June 2013 8
  9. 9. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Solution (filter/LEV not possible) Plenum Rubber Curtains Ref: Wypych, 1995 © Wypych, 2013 Passive Enclosure Dust Control System Pressure Relief System Ref: US Patent US6135171 (2000) © Wypych, 2013 4 June 2013 9
  10. 10. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong PREVENTION: (2) Improved Solids-Air Flow Prediction and Control  To Minimise/Avoid:  Surges and/or Peak Product Flows (Velocity Variations)  Minimise Air/Dust “Surges”  Unnecessary Impacts & Dust Generation e.g. Conveyor Transfer © Wypych, 2013 Validated DEM Simulation: Calibration (Hopper Flow  Sliding/Rolling Friction) Video Video  Compare: ms, heap and velocity profiles) © Wypych, 2013 4 June 2013 10
  11. 11. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Bulk Material Calibration for DEM (particle shape, friction, cohesion) New “Swing Arm” Slump Tester Video Video © Wypych, 2013 Other Special Calibration Tests for DEM Design © Wypych, 2013 4 June 2013 11
  12. 12. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Large-Scale “Dynamic” Validation Conveyor Transfer Facility     Validation of DEM Scale-Up Investigations CT Design & Testing Thanks to ARC & Rio Tinto © Wypych, 2013 Validated DEM of Hood-Spoon CT Video © Wypych, 2013 4 June 2013 12
  13. 13. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Validated DEM of Impact Plate CT  Particle Velocity  Impact Reaction Video © Wypych, 2013 Impact-Plate Conveyor Transfer Video © Wypych, 2013 4 June 2013 13
  14. 14. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong Case Study: 5000tph Ship Loader Dry Wet Video Video © Wypych, 2013 Case Study: 5000tph Ship Loader (Concept Design Option No. 3) Video © Wypych, 2013 4 June 2013 14
  15. 15. BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong 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 Case Study could NOT be presented due to reduced time allowed…to be covered at Workshop D (6 June 2013) © Wypych, 2013 Thank You !! Peter Wypych wypych@uow.edu.au 4 June 2013 15

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