Using Dry Fog at Coal Crushers to replace dust collection and chemical spray systems has yielded excellent results. In addition to increased dust control, plants report that the costs of O&M can be up to 4 times lower than collection. Dry Fog does not require changing bags, leaves no duct-work to maintain, nor are there any secondary explosive waste streams to manage. Additionally, energy consumption is much lower.
The same is true for screening systems, where Dry Fog can be used without creating material flow problems often associated with chemical spray systems. Because Dry Fog wets the airborne dust, not the coal ore, it will not blind your screens.
Preventing dust generation at Storage Piles is becoming an increasing priority and is a concern beyond environmental compliance. The DustTAMER Wind Fence System can reduce the amount of air infiltration into a coal pile. At Storage Piles, air infiltration is a major contributor to PRB coal fragmentation and contributes to the risk of spontaneous combustion.
Spraying water onto the pile can also add to spontaneous combustion risk. DustTAMER can reduce or eliminate the need for watering. If a coal pile is treated with water or chemicals, DustTAMER can slow the evaporation and drying effect, allowing for infrequent watering, saving time and BTUs.
EPA has declared wind barriers as a dust control measure that can be used for a fugitive coal dust emissions control plan. This emissions control plan is now required for open storage piles for plants constructed, re-constructed or modified after May 27, 2009.
DustTAMER is a much less expensive alternative to Chemical Treatment, Domes and Buildings. Our fabric is designed to withstand winds in excess of 100 MPH and is resistant to the effects of UV Rays. Some installations are approaching 20 years of service with no significant fabric deterioration.
Silo fill areas are typically areas of high concern in regards to preventing dust explosions. Switching to PRB Coal increases this risk. Dry Fog has dramatically reduced dust explosion hazards at tripper conveyors and gallery silo fill systems by replacing old dust collection systems.
Preventing the creation of airborne dust reduces the amount of dust that accumulates on the surrounding structures and equipment. A typical explosion event starts with a process equipment failure that provides the "spark" to create internal deflagration. This creates a shock-wave that rebounds inside the facility, turning latent dust into a dust cloud. The dust cloud then creates a larger deflagration event and results in an explosion. All of this can occur in a matter of 1/3 of a second! The good news is our customers report that they are able to more than triple the time between wash-downs. This saves time and money while complying with OSHA regulations.
Recent dust explosion incidents have resulted in the OSHA Fire Safety Program Combustible Dust National Emphasis Program which incorporates 25 existing OSHA, NFPA and FM standards. Non-compliance can result in fines as high as $8.4 million.
Baghouse fires were previously a common occurrence and great concern at PRB Coal Mines. Replacing these systems with Dry Fog Systems is now a common solution, including at silo fill systems. The same is true at PRB Coal-Fired Power Plants.
Baghouse discharge points can be eliminated by replacing the baghouse with a Dry Fog System. However, there are times when a customer must keep the baghouse and use a Dry Fog System to control the collected dust that is being purged from the baghouse. In these cases, an enclosure at the discharge baghouse point must be large enough to allow for sufficient retention time of the fog and dust. This will enable agglomeration to occur.