Dust Control Handbook for Industrial Minerals Mining and Processing

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TABLE OF CONTENTSACRONYMS AND ABBREVIATIONS USED IN THIS HANDBOOK ....................................... xxiiiUNIT OF MEASURE ABBREVIATIONS USED IN THIS HANDBOOK .................................. xxivACKNOWLEDGMENTS ............................................................................................................. xxvABOUT THIS HANDBOOK ...................................................................................................... xxviTASK FORCE COMMITTEE COCHAIRS............................................................................... xxviTASK FORCE COMMITTEE MEMBERS ............................................................................... xxviEDITOR ................................................................................................................................. xxviiHANDBOOK LAYOUT COORDINATOR ............................................................................. xxviiIMA-NA COORDINATOR ..................................................................................................... xxviiINTRODUCTION ........................................................................................................................... 1SILICA EXPOSURE AND POTENTIAL HEALTH IMPACTS ...................................................... 2REFERENCES ............................................................................................................................. 4CHAPTER 1: FUNDAMENTALS OF DUST COLLECTION SYSTEMS ...................................... 7BASICS OF DUST COLLECTOR SYSTEMS ............................................................................... 8AIRFLOW AND DUST CONTROL .............................................................................................. 9EXHAUST SYSTEMS DESIGN ................................................................................................. 11HOODS ..................................................................................................................................... 11Hoods and Blowing versus Exhausting Ventilation ........................................................................... 11Hood Types .............................................................................................................................. 12Hood Design ............................................................................................................................. 14Air Induction ........................................................................................................................ 15Capture Velocity .................................................................................................................... 16Other Hood Considerations .......................................................................................................... 18Checklist for Hood Effectiveness .................................................................................................. 19DUCTWORK AND AIR VELOCITIES ....................................................................................... 19High-Velocity Systems ............................................................................................................... 20Low-Velocity Systems ................................................................................................................ 21Airflow Target of 1,800 fpm .................................................................................................... 23Avoidance of Horizontal Ductwork ........................................................................................... 23The Use of Main Duct Trunk Lines ........................................................................................... 24v
Minimizing Field Fits and Welds .............................................................................................. 24Avoiding Mitered Elbows Greater Than 90 Degrees ..................................................................... 25Sizing and Locating Orifice Plates ............................................................................................. 25Minimizing the Use of Flexible Hoses ....................................................................................... 26Modified Low-Velocity (MLV) System ......................................................................................... 26AIR CLEANING DEVICES ........................................................................................................ 28Gravity Separators (Drop-Out Boxes) ............................................................................................ 28Centrifugal Collectors or Cyclones ................................................................................................ 29Baghouse Collectors ................................................................................................................... 31Mechanical Shaker Collectors .................................................................................................. 34Reverse Air Collectors ............................................................................................................ 36Reverse Jet (Pulse Jet) Collectors .............................................................................................. 37Cartridge Collectors ............................................................................................................... 38Wet Scrubbers ........................................................................................................................... 40Venturi Scrubbers .................................................................................................................. 41Impingement Plate Scrubbers ................................................................................................... 41Spray Tower Scrubbers ........................................................................................................... 42Wet Cyclone Scrubbers ........................................................................................................... 42Electrostatic Precipitators (ESPs) .................................................................................................. 42COLLECTOR DISCHARGE DEVICES ...................................................................................... 43Rotary Airlock Valves ................................................................................................................ 43Double Dump Valves ................................................................................................................. 43Tilt Valves ................................................................................................................................ 44Vacuum or Dribble Valves........................................................................................................... 44FILTER FABRICS ..................................................................................................................... 44Particulate Collection of Fabrics ................................................................................................... 46DESIGNING MINE/PLANT DUST COLLECTION SYSTEMS ................................................... 48Clay Application ........................................................................................................................ 49FANS ......................................................................................................................................... 50Fan Operating Characteristics ....................................................................................................... 50Fan Laws ................................................................................................................................. 52Fan Types................................................................................................................................. 53Axial-Flow Fans .................................................................................................................... 53vi
Page 2 and 3: Report of Investigations 9689Dust C
Page 4: FUNDAMENTALS OF DUSTCOLLECTION SYST
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 and 16: ILLUSTRATIONSFigure 1.1. Relationsh
Page 17 and 18: Figure 3.2. The air and water flow
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
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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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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
Page 310 and 311:
Open structure building design. A p
Page 312 and 313:
Table bushing. A bushing used to se
Page 314:
Delivering on the Nation’s promis
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Dust Control Handbook for Industrial Minerals Mining and Processing

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