Dust Control Handbook for Industrial Minerals Mining and Processing

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caused during manufacturing, including improper gluing and improper storage of empty bags,are just a few of the factors that can cause bag breakage. The location of the break has asignificant impact on the amount of dust liberated. Bags that break during filling tend to be moreviolently affected than those that break during ejection or conveying. In all cases, bag breakageliberates a substantial amount of dust and significantly impacts workers in these areas.Figure 6.2. Typical bag valve—interior view (left). Artist concept of fill nozzle and bagvalve (right). Fill nozzle enters through the bag valve and delivers product into bag.BAG CONSIDERATIONSA number of different factors ultimately impact the amount of dust generated or liberated frombags of product material: bag construction, bag perforations, bag fill type, and the effects frombag failures.Bag ConstructionThe multi-wall pasted valve bag is by far the most common bag used for the packaging ofmineral products and is the only style discussed below. Many of the considerations discussed forpasted valve bags are also applicable to open-top bags.A very important element in controlling the amount of dust liberated during the bagging processis the design and construction of the paper bag itself. The composition of the paper, its porosity,the number of plies or layers used, the "basis weight/thickness" of the paper sheets whichprovides strength, the type of pasted valve, and the use of bag perforations, are all factors thataffect and can minimize the amount of dust generated or liberated from the bag.One area of significant advances by bag manufacturers over the years has been the improvementsand advances in "paper" technology [Kearns 2004]. Currently, conventional natural kraft (NK)paper, also known as flat kraft (FK) paper, is the industry standard. Normal constructions for 50 -to 100-pound bags are to use either three or four plies of NK paper. Due to the low porosity ofNK paper, meaning that air does not flow through the paper material, bag perforations areBagging 159
normally required for most industrial mineral processing applications to keep the bag fromrupturing/exploding.Another development in paper technology is the use of extensible kraft (EK) paper, sometimesreferred to as "high performance paper." The strength of this EK paper has been increased tosuch an extent that the number of plies can be reduced by approximately 30 percent in multilayerbags when compared to conventional kraft papers. A savings in paper can be achieved inone of two ways. The first, and the most common approach, is to reduce the number ofplies/layers in the bag. For instance, rather than using NK or FK paper that would normallyrequire three or four plies/layers to obtain the needed strength, by using EK paper, the number ofplies/layers can normally be reduced down to just two. For every ply/layer that is reduced, thereis a benefit from an increase in the bag's porosity, thus allowing the bag to breathe better.Despite its popularity, extensible kraft paper does not allow for the proper ventilation requiredfor many packaging applications; therefore, bag perforations are still required to provide thenecessary air escape during bagging to avoid ruptures. The second way to reduce paper is byreducing the weight/thickness of each ply/layer of paper.Airflow extensible kraft (AEK) paper was developed in the 1990s and offers the same crossdirectionaland machine directional strength as EK paper, but with an air-permeable (breathable)characteristic. A great benefit from this air-permeability characteristic is that it eliminates therequirement for void spaces in the bag construction, allowing for a smaller bag size. The porouspaper is superior to perforated paper as far as strength and air evacuation (ability to relieve airpressure). No bag perforations are required when using this AEK paper type, and by eliminatingperforations, bag strength can be increased by as much as 20 percent. The faster the air isevacuated from bags, the faster they can be filled and palletized, thus increasing production andprofitability.The AEK paper also allows the flow of air to depressurize the bag at a rate of three to four timesfaster than standard kraft (NK or FK) paper and at the same time retains bag strength. The paperacts as a filter during the bag filling process which allows the product to flow freely into the bagwhile containing dust that could be liberated into the work environment and expose workers.Because of this, the outer surface of the bag stays cleaner. When considering the various optionsavailable for bag construction, the use of AEK paper appears to be the best choice to minimizethe amount of dust generated and liberated from the bag during the filling process.Bag PerforationsAs product enters the paper bag during the filling process, fluidizing air entrapped in the productmust be evacuated in order to fill the bag with product. In order to remove the air as the productis introduced into the bag, perforations or vent holes are integrated in the paper used in the bag.For this purpose, manufacturers use multi-wall bag perforations, which are small vent holespunched through the walls of the paper bag to allow air to escape rapidly during the fillingprocess.There are two common types of perforations used in bags: overall perforations and undervalveperforations. Both types of perforations reduce the strength of a paper bag by as much as20 percent.160 Bagging
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Report of Investigations 9689Dust C
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FUNDAMENTALS OF DUSTCOLLECTION SYST
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Minimizing Field Fits and Welds ...
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Recommendations for Proper Wet Dril
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CONTROL TECHNOLOGIES FOR FILLING 50
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Effective Filtration ..............
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ILLUSTRATIONSFigure 1.1. Relationsh
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Figure 3.2. The air and water flow
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Figure 9.5. Problem created by heat
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UNIT OF MEASURE ABBREVIATIONSUSED I
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Robert J. Franta, Quotation Enginee
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silica. Quartz is the most common s
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DUST CONTROL HANDBOOK FOR INDUSTRIA
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CHAPTER 1: FUNDAMENTALS OFDUST COLL
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The shape of particles affects how
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EXHAUST SYSTEMS DESIGNAll exhaust s
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stripping, which allows workers to
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When using the air quantities in Ta
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X = distance in feet from the face
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Checklist for Hood EffectivenessThe
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A major disadvantage of the high-ve
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A common misconception when designi
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Avoiding Mitered Elbows Greater Tha
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Figure 1.13. Depiction of the horiz
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Figure 1.14. Typical design of grav
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Baghouse CollectorsBaghouse dust co
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Table 1.2. Emission factors for cru
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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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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
Page 137 and 138: USBM [1995]. The reduction of airbo
Page 139 and 140: 110 Drilling and BlastingDUST CONTR
Page 141 and 142: Wet Control MethodsPREVENTION AND S
Page 143 and 144: Figure 4.2. Examples of compressive
Page 145 and 146: Figure 4.5. Illustration of a dry (
Page 147 and 148: Figure 4.6. Illustration of a dry (
Page 149 and 150: Wet dust control methods for crushi
Page 151 and 152: Work Practices to Minimize Dust Exp
Page 153 and 154: Some specialty grinding operations
Page 155 and 156: should be frequently inspected for
Page 157 and 158: Open screen decks slowly to allow i
Page 160 and 161: DUST CONTROL HANDBOOK FOR INDUSTRIA
Page 162 and 163: CHAPTER 5: CONVEYING AND TRANSPORTT
Page 164 and 165: Figure 5.3. Basic depiction of mate
Page 166 and 167: that the material falls before land
Page 168 and 169: Figure 5.10. Skirtboard used within
Page 170 and 171: CarrybackMaterial that sticks or cl
Page 172 and 173: CONVEYOR DESIGN AND MAINTENANCE ISS
Page 174 and 175: Figure 5.15. Conveyor transfer encl
Page 176 and 177: High-volume, high-pressure sprays s
Page 178 and 179: Figure 5.19. Depiction of a bucket
Page 180 and 181: Figure 5.21. Depiction of two types
Page 182 and 183: Figure 5.25. Venturi eductor utiliz
Page 186 and 187: CHAPTER 6: BAGGINGThis chapter disc
Page 190 and 191: Overall PerforationsThe use of over
Page 192 and 193: Figure 6.5. Open-top bag being load
Page 194 and 195: Bagging operators should be aware t
Page 196 and 197: Figure 6.8. Exhaust hood to capture
Page 198 and 199: In the original design, a single no
Page 200 and 201: The OASIS is a relatively simple de
Page 202 and 203: Figure 6.13. Bag storage shelves sh
Page 204 and 205: Figure 6.14. Bag and belt cleaner d
Page 206 and 207: other industrial application using
Page 208 and 209: The robotic arm automatic palletize
Page 210 and 211: For many years, this plastic wrappi
Page 212 and 213: warehouse location until a later ti
Page 214 and 215: used successfully to perform this c
Page 218 and 219: CHAPTER 7: BULK LOADINGDuring the b
Page 220 and 221: Figure 7.2. Loading spout discharge
Page 222 and 223: Cascading Loading SpoutFigure 7.5 i
Page 224 and 225: a seal at the entry and exit points
Page 226: REFERENCESBiere G, Swinderman RT, M
Page 229 and 230: 200 Bulk LoadingDUST CONTROL HANDBO
Page 231 and 232: many years, as well as some new and
Page 233 and 234: Figure 8.2. Air spray manifold desi
Page 235 and 236: Figure 8.3. Test subject wearing po
Page 237 and 238: 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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