Dust Control Handbook for Industrial Minerals Mining and Processing

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Figure 1.28. Wall-mounted propeller fan .................................................................................... 53Figure 1.29. Typical tubeaxial fan (left) and vaneaxial fan (right) .............................................. 54Figure 1.30. Typical centrifugal fan ............................................................................................ 55Figure 1.31. Axial centrifugal fan showing airflow ..................................................................... 56Figure 1.32. Typical roof ventilators using axial fans (left) and centrifugal fans (right) ............ 57Figure 2.1. Common dust control application illustrating nozzle positioning ............................. 62Figure 2.2. Effect of droplet size on dust particle impingement .................................................. 63Figure 2.3. Contact angle resulting from a liquid meeting a solid surface .................................. 65Figure 2.4. Typical internal mix nozzle (top) and external mix nozzle (bottom) ........................ 66Figure 2.5. Typical air atomizing nozzle round spray pattern (top) and fan spray pattern(bottom) .................................................................................................................................... 66Figure 2.6. Typical full cone nozzle and spray pattern ................................................................ 67Figure 2.7. Typical hollow cone whirl chamber nozzle and spray pattern. Right angle designshown ........................................................................................................................................ 67Figure 2.8. Typical hollow cone spiral nozzle and spray pattern ................................................ 68Figure 2.9. Typical flat fan nozzle and spray patterns ................................................................. 68Figure 2.10. Typical loader dump dust control application ......................................................... 69Figure 2.11. Typical conveyor dust control application .............................................................. 69Figure 2.12. Airborne suppression performance of four types of spray nozzles and flat fanspray nozzles are hydraulically atomizing ............................................................................... 70Figure 2.13. Typical self-contained water delivery system ......................................................... 71Figure 2.14. Typical duplex basket strainer ................................................................................. 72Figure 2.15. Nozzle erosion—new versus used ........................................................................... 72Figure 2.16. Nozzle corrosion—new versus used ....................................................................... 73Figure 2.17. Nozzle caking—new versus used ............................................................................ 73Figure 2.18. Temperature damage—new versus used ................................................................. 73Figure 2.19. Nozzle damage—new versus used .......................................................................... 74Figure 2.20. Good spray tip showing pattern and distribution graph. Height of bar indicatesdistribution of water over pattern width and indicates relatively uniform flow over thewidth of the pattern ................................................................................................................... 74Figure 2.21. Worn spray tip showing pattern and distribution graph. Height of bar indicatesdistribution of water over pattern width and indicates an increase of and excessive flow inthe center of the pattern due to orifice wear ............................................................................. 74Figure 3.1. Illustrations depicting a small surface crawler drill rig, a truck-mounted drill rig,and a large track-mounted drill rig, respectively ...................................................................... 80xv
Figure 3.2. The air and water flow during drilling operation to demonstrate water flushingof the drill cuttings. The water flows through the center of the drill steel and out the endof the drill bit to remove the cuttings from the drill hole ......................................................... 81Figure 3.3. Internal workings of a water separator sub................................................................ 83Figure 3.4. A basic dry dust collection system on a drill ............................................................. 84Figure 3.5. Reinforcing flaps added to each corner of a rectangular deck shroud to reduceleakage ...................................................................................................................................... 85Figure 3.6. Circular shroud design ............................................................................................... 86Figure 3.7. Results of changing dust collector to bailing air ratio at various shroud gapheights ...................................................................................................................................... 87Figure 3.8. Graphs of the model that represents the severity of dust emissions based uponcollector to bailing airflow ratios, showing that the respirable dust concentrations becomelower as the collector to bailing airflow ratio increases ........................................................... 89Figure 3.9. Qualitative models of airflow patterns underneath the shroud without the airblockingshelf (left) and with the air-blocking shelf (right) ..................................................... 90Figure 3.10. Air-blocking shelf installed on the inside perimeter of the drill shroud of ablasthole drill. Note the overlap in the rear corners to eliminate any gaps in the shelfperimeter ................................................................................................................................... 91Figure 3.11. Buildup of material on the air-blocking shelf (left) and the resulting dustemissions that are created during lowering of the drill mast (right) ........................................ 92Figure 3.12. Air-blocking shelf with modifications incorporated into installation. Thisshelf was installed in short sections in an attempt to prevent potential damage that couldoccur during tramming with the drill mast up .......................................................................... 92Figure 3.13. Dust collector dump point prior to shroud installation (A). Two men installingthe shroud onto the dust collector dump point (B). The dust collector dump point afterinstallation of the shroud (C) .................................................................................................... 93Figure 3.14. Comparison of dust concentrations of uncontrolled dust collector dump toshrouded dust collector dump ................................................................................................... 94Figure 3.15. Air ring seal used to impede the movement of dust particles through an opening . 96Figure 3.16. Typical dust collection system used by small crawler or "buggy" drills ................ 97Figure 3.17. Illustrations showing a typical jackleg drill, stoper drill, and 3-boom jumbo,respectively ............................................................................................................................... 98Figure 3.18. Water flow during a drilling operation to demonstrate water flushing of the drillcuttings. The water flows through the drill into the center of the drill steel and out the endof the drill bit to remove the cuttings from the drill hole ......................................................... 98Figure 3.19. Drill boom showing external water sprays directed onto the drill steel ................ 100Figure 3.20. A typical blasthole containing an explosive charge utilizing a water cartridge tosuppress dust generated during blasting ................................................................................. 102xvi
Page 2 and 3: Report of Investigations 9689Dust C
Page 4: FUNDAMENTALS OF DUSTCOLLECTION SYST
Page 7 and 8: Minimizing Field Fits and Welds ...
Page 9 and 10: Recommendations for Proper Wet Dril
Page 11 and 12: CONTROL TECHNOLOGIES FOR FILLING 50
Page 13 and 14: Effective Filtration ..............
Page 15: ILLUSTRATIONSFigure 1.1. Relationsh
Page 22: Figure 9.5. Problem created by heat
Page 25 and 26: UNIT OF MEASURE ABBREVIATIONSUSED I
Page 28: Robert J. Franta, Quotation Enginee
Page 32 and 33: silica. Quartz is the most common s
Page 34 and 35: DUST CONTROL HANDBOOK FOR INDUSTRIA
Page 36 and 37: CHAPTER 1: FUNDAMENTALS OFDUST COLL
Page 38 and 39: The shape of particles affects how
Page 40 and 41: EXHAUST SYSTEMS DESIGNAll exhaust s
Page 42 and 43: stripping, which allows workers to
Page 44 and 45: When using the air quantities in Ta
Page 46 and 47: X = distance in feet from the face
Page 48 and 49: Checklist for Hood EffectivenessThe
Page 50 and 51: A major disadvantage of the high-ve
Page 52 and 53: A common misconception when designi
Page 54 and 55: Avoiding Mitered Elbows Greater Tha
Page 56 and 57: Figure 1.13. Depiction of the horiz
Page 58 and 59: Figure 1.14. Typical design of grav
Page 60 and 61: Baghouse CollectorsBaghouse dust co
Page 62 and 63: Table 1.2. Emission factors for cru
Page 64 and 65: Figure 1.17. Typical design of a me
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Reverse Jet (Pulse Jet) CollectorsR
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Figure 1.20. Cartridge collector wi
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Wet scrubbers are particularly adva
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Electrostatic precipitators normall
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may be related to specific applicat
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times. When considering the depth o
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Figure 1.25. Demonstration of how a
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Figure 1.26. A typical fan performa
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Fan TypesThere are two basic types
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Figure 1.30. Typical centrifugal fa
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Figure 1.32. Typical roof ventilato
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DUST CONTROL HANDBOOK FOR INDUSTRIA
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The vast majority of dust particles
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Table 2.1. Particle/droplet size in
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Air Atomizing NozzlesAir atomizing
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Hydraulic Flat Fan NozzlesFigure 2.
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for dust knockdown or suppression,
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Nozzle MaintenanceFigure 2.14. Typi
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Accidental DamageInadvertent harm t
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NDT Educational Resource Center, Io
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78 Wet Spray SystemsDUST CONTROL HA
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contains a piston which delivers ha
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produce an increase in the penetrat
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Dry DrillingDry drilling is accompl
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Circular ShroudIn contrast to the u
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The collector airflow has a more su
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Air-Blocking ShelfThe air-blocking
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dust emissions from mast lowering,
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This simple procedure of creating a
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Figure 3.15. Air ring seal used to
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Figure 3.17. Illustrations showing
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unsubstantiated due to the inconsis
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safety considerations may preclude
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Figure 3.22. A filtration unit, loc
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Miller S, Emerick JC, Vogely WA [19
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USBM [1995]. The reduction of airbo
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110 Drilling and BlastingDUST CONTR
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Wet Control MethodsPREVENTION AND S
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Figure 4.2. Examples of compressive
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Figure 4.5. Illustration of a dry (
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Figure 4.6. Illustration of a dry (
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Wet dust control methods for crushi
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Work Practices to Minimize Dust Exp
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Some specialty grinding operations
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should be frequently inspected for
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Open screen decks slowly to allow i
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CHAPTER 5: CONVEYING AND TRANSPORTT
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Figure 5.3. Basic depiction of mate
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that the material falls before land
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Figure 5.10. Skirtboard used within
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CarrybackMaterial that sticks or cl
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CONVEYOR DESIGN AND MAINTENANCE ISS
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Figure 5.15. Conveyor transfer encl
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High-volume, high-pressure sprays s
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Figure 5.19. Depiction of a bucket
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Figure 5.21. Depiction of two types
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Figure 5.25. Venturi eductor utiliz
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CHAPTER 6: BAGGINGThis chapter disc
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caused during manufacturing, includ
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Overall PerforationsThe use of over
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Figure 6.5. Open-top bag being load
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Bagging operators should be aware t
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Figure 6.8. Exhaust hood to capture
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In the original design, a single no
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The OASIS is a relatively simple de
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Figure 6.13. Bag storage shelves sh
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Figure 6.14. Bag and belt cleaner d
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other industrial application using
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The robotic arm automatic palletize
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For many years, this plastic wrappi
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warehouse location until a later ti
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used successfully to perform this c
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CHAPTER 7: BULK LOADINGDuring the b
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Figure 7.2. Loading spout discharge
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Cascading Loading SpoutFigure 7.5 i
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a seal at the entry and exit points
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REFERENCESBiere G, Swinderman RT, M
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200 Bulk LoadingDUST CONTROL HANDBO
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many years, as well as some new and
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Figure 8.2. Air spray manifold desi
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Figure 8.3. Test subject wearing po
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Spills of product material are a co
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epetitive dust leaks should not sim
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Effective Upward Airflow PatternThe
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Figure 8.8. Open-structure design c
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manually removing the bags and plac
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Figure 8.12. Increase in worker’s
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In other cases, an operation may wa
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Cecala AB, O'Brien AD, Pollock DE,
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224 Controls for Secondary SourcesD
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where C o = outside respirable dust
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minimal improvement in the cab's ai
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RECOMMENDATIONS FOR FILTRATION/PRES
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Effective FiltrationFigure 9.4. Res
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average decay times were between 16
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Figure 9.6. Filtration unit showing
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This table highlights a number of c
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NIOSH [2001b]. Technology news 486:
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upon the wind velocity (or disturba
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Maximum size is the largest particl
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Figure 10.4. Use of end-dumping wit
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conditions. Performance of each of
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A water truck, used to apply water
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Surfactants work by reducing the su
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which differed for the various site
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Figure 10.9. Self-tarping dump truc
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percent [Fryrear and Skidmore 1985]
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Figure 10.12. The armoring process
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A current method of stockpile forma
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Figure 10.15. Demonstration of how
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Chekan GJ, Cecala AB, Colinet JF [2
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Midwest Research Institute [1981].
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GLOSSARYAbrader. An implement used
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Carryback. Material that sticks or
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End-dumping. A process of spreading
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Open structure building design. A p
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Table bushing. A bushing used to se
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Delivering on the Nation’s promis
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