Reducing dust from Stack-Out operations can be challenging. The elevation of the Stacking conveyor above the discharge point is a major factor in how we approach the problem. Solutions can include using a combination of the following measures: Dry Fog™, Wet Suppression, Strip Curtains and DustTamer™ Wind Fence Systems.
At DSI we take a comprehensive approach because there are multiple sources of dust from stackers. Dust that is separated from the ore and settles out onto the belt is the first to become airborne when it discharges from the stacker head.
Ambient wind separates more dust from the ore as it falls and
then more dust is generated as it impacts the storage pile.
Dry Fog™ can virtually eliminate dust issues from loading rail cars and trucks at mine facilities. DSI has designed a variety of system to control dust for coal, pet-coke, copper, limestone and other dusty materials when loading trucks or rail cars for overland transport.
Truck Dumps and Rail Car Dumps can be a very significant source of dust. Collecting dust from large open dump pockets is very difficult. Cost for collection systems can exceed $1,000,000 and still the user is faced with what to do with the collected dust. Chemical systems require use of expensive chemicals and are not effective in removing dust from the air. Furthermore, sprays create large water droplets that will freeze, making wintertime operations in many regions impossible. Dry Fog Systems can effectively capture airborne dust, returning it to the dump pocket, without wetting the material. Dry Fog™ will not freeze and can operate in temperatures as low as –35% F.
DSI has provided fogging systems to various types of mines including Coal, Copper, Gold, Sliver, Limestone, Zinc and more. Applications range from front end loader dumps to large 340 ton haul trucks dumping into primary crushers.
DSI has successfully controlled dust from a variety of material handling operations. One common application is Feed Hoppers. If the dust can be contained within the material handling system, a facility can come into compliance, reduce operating cost and increase operator safety.
Dry Fog™ Systems can help contain dust generated from loaders and trucks dumping into hoppers and reclaim feeders. If the hopper is in the open, we can combine Dry Fog with DustTamer™ Wind Screens to reduce the effects of ambient wind.
Dry Fog™ is used extensively at the largest mines in the world. Many of these projects are in South America. However, they are still required to meet or exceed U.S. EPA Air Quality Regulations. Typically, these mines are in remote locations where electrical power and water are at a premium. Dry Fog systems use very little water with nozzles rated in Gallons Per Hour (not minute).
Studies have shown that the cost of operation and maintenance of Dry Fog systems are approximately 25% of that of a collection system (see Mine cost study). Dry Fog will not freeze and can operate in temperatures as low as –35 F.