Mason Trouchet, Rainstorm Dust Control - Action to Prevent Fugitive Dust

Dust Control

Materials

Handling Week May 2013

Mine Site Dust

Control

One

• Developing “Real time Dust Control Plans”

• Conducting frequent audits to assess operating

conditions relating to dust management plans.

Mine Site Dust

Control

Two

• Real time dust monitoring

Mine Site Dust

Control

Three

• Air quality modelling

Mine Site Dust

Control

Four

• Utilising weather prediction and forecasting to prevent

dust generation at source

Mine Site Dust

Control

METHODS OF DUST PREVENTION

Objectives:

Prevent dust from becoming fugitive in the first

place.

• Wet dust suppression using water.

• Chemical dust suppression.

Capture or drop fugitive dust from atmosphere

• Mechanical dust suppression.

Mine Site Dust

Control


Ventilation

• Increase the airflow to dilute dust from environment

Containment

• Dust is trapped in a enclosure, filter system, negative

pressure inside a building.

Mine Site Dust

Control


Extraction and filtration

• Airborne dust is extracted and filtered from the air

Suppression

• Water / additives

Mine Site Dust

Control


Wind barriers and diffusers

• Natural or artificial barriers placed in strategic

positions to reduce velocity.

Design

• Plant, equipment and process to minimise dust

generation.

• Prevention of dust from becoming airborne in the first

place is addressing the root cause and is the most

critical aspect of good dust management.

Mine Site Dust

Control


Objectives;

Prevent dust from becoming fugitive in the first

place. Abatement strategy.

• Wet dust suppression using water.

• Water is commonly used to control dust.

Considerations of the cost benefit have changed over

the past 5 years.

• Water on dust control is water lost

Mine Site Dust

Control


Chemical dust suppression

• Water absorbing

• Wetting agents (water extender surfactants)

• Foaming agents.

• Binding / agglomerating agents

• Veneer agents (crusting agents)

• Petroleum based

• Electrochemical

• Polymer

• Starch

• Cellulose

• Clay additives

Mine Site Dust

Control

Areas of concern:

• Roads and trafficable areas. Single largest dust

generation point

• Open areas and stockpiles second largest dust

generation point

• Materials handling third largest dust generation point

Objectives:

• Prevent dust from becoming fugitive in the first place.

• Capture or drop fugitive dust from atmosphere

• Manage dust control programs

• Environmental reporting and compliance

Mine Site Dust

Control


• Water

Considerations

• Water quality

• Ease of use and effectiveness to wet surface areas of

substrate material.

Advantages:

• Sometimes easily obtained and inexpensive.

• Feed equipment relatively inexpensive to install.

• Good short term dust suppression, assuming the dust

particles are contacted and wetted.

• Normally readily available.

• Agglomerates the surface particles.

• Low environmental impact.

Mine Site Dust

Control

Disadvantages.

• Water on dust control is water lost. Unsustainable

practice - no water is recycled in dust control activity.

• Dust control short term, ½ hour to 12 hours

• Does not easily wet many substrates, resulting in

inefficient dust control.

• Improper use results in material handling problems,

such as freezing, belt carry-back, crushing and

screening hang-ups, throughput downtime loss.

• Cost of water carts and the water.

• Loss of water - Environmental impact

• Volume of water, DEM moisture control.

• Shipping moisture restrictions.

Mine Site Dust

Control

Roads and Trafficable Areas

• Optimising water usage in dust suppression on haul

roads, and exploring cost effective alternative options.

• Roads and trafficable areas

• Application tips and considerations.

• Access roads.

• Haul roads.

• “Shandy Mixing”

• Water cart / dust control teams and control.


Roads

• Water carts • Record the process. • Manage and report • Signage • Application tips • Flexible vs. Rigid • Count the water • Maintenance • Costing rate / m2 / frequency / cost of product


Dustmag

Mine Site Dust

Control


• Water absorbing (deliquescent / hygroscopic)

• Dustmag

Mine Site Dust

Control



• Dustmag

Attributes

• Starts to absorb water from the air at relatively low

humidity and high temperatures.

• Suitable for underground.

• Increasing surface tension between particles slows

evaporation further tightening as drying progresses

Mine Site Dust

Control



• Dustmag

Attributes

• Treated roads can be regraded and will self-heal

under traffic with less concern for losing moisture and

density.

• Free rolling resistance results in less tyre damage.

• More suitable in drier climates.


Dustmag


Dustmag


Dustmag


Dustmag


Dustmag


Dustmag

• Count the water allocation

Water Calculator Road Dust Suppresion

Water

m2 Water volume L Litres per m2

25000 62,500 2.5


Dustmag

• Cost the water cart consider rate to area WATERCART COST WORKSHEET

12 WEEKS DUST SUPPRESSION BUDGET

A) Number of Watercarts 1

B) AVERAGE Watercart Cost per Hour $230

C) Hours per Day 10

D) Watercart Cost per Day = A x B x C $2,300

E) Days of Use per Week 7

F) Number of Weeks of Use 12

G) TOTAL COST OF WATERCART(S) = D x E x F $193,200

H) Length of Road (metres) 8000

I) Width of Road (metres) 25

J) AREA OF ROAD (square metres) = H x I 200000

K) TOTAL WATERCART COST PER SQUARE METRE = G / J $0.97

L) COST OF DUSTMAG PER SQUARE METRE $0.900

M) COST SAVINGS per Sq.M. OF DUSTMAG vs. WATERCARTS = K - L $0.07

N) TOTAL COST SAVINGS OF DUSTMAG vs. WATERCARTS = M x J $13,182


Dustmag

• Cost the water cart consider rate to area


Application tips

• Evaluate what application program will fit with your workplace environment.

• Top down surface application

• Pavement mix.

• Application frequency

• Compaction

• Road condition during application

• Rain events

Mine Site Dust

Control


• Binding / Agglomerating agents

• Polymers (PVA) Polyvinyl Acetate, Vinyl Acrylic

Attributes

• Agglomerates and binds the surface particles

together, because of polymer adhesive properties.

• Serves to water proof the road.

• Can be used as Veneer coating for non-traffic and

rehabilitation areas.

• Versatile

Mine Site Dust

Control


• Binding / Agglomerating agents

• Polymer (PVA) Polyvinyl Acetate, Vinyl Acrylic

Limitations

• Difficult to maintain hard surface.

• Requires higher frequency top up for dust control than

Dustmag.

Application

• Mixed into pavement and applied as a top coat.

• 50% residual concentrate applied 1:10 with water.

• Target rate 300 ml/ m2 concentrate for each 50mm

depth.

• Top coats mix 2 L/m2.

Environmental Impact

• None expected.


Polymag Dustmag Gluon

• Top down surface application

• Pavement mix.

• Application frequency

• Compaction

• Road condition during application

• Rain event

• Maintenance to Rigid pavements


Polymag Paczyme


Polymag Paczyme Betta Wett

Mine Site Dust

Control


• Electrochemical Derivatives

• Paczyme Organic

Attributes

• Agglomerates and binds the surface particles.

• Changes characteristics of clay size particles.

• Extends water penetration and efficiency, slows

evaporation.

• Increased MDD (Max Dry Density).

• Organic suitable for use in sensitive environmental

conditions.

• Lowers permeability in expansive clay soils.

• Reduced hydration cracking.

• Concentrated format.

Mine Site Dust

Control



• Paczyme Organic

Limitations

• Performance dependent on fine clay mineralogy.

• Needs to dry cure to set.

• Difficult to maintain if full setting strength is achieved.

• Limited life span.

Application

• Diluted with water between 1:500 to 1:1000

• 1L to treat 30m3.

• Diluted to compaction agent.

Mine Site Dust

Control



• Paczyme Organic

Origin

• Enzymes, ionic products, sulphonated oils,

ammonium chloride.

Environmental Impact

• Need specific product analysis.

• Some products highly acidic in concentrated,

undiluted form.

Mine Site Dust

Control


• Wetting agents (foams and water extenders)

• Surfactants “Betta Wett”

Attributes

• Concentrated format.

• Extends water penetration.

• Slows evaporation, suitable additive to polymer

applications.

• Foaming formulations.

Limitations

• Limited life span.

Mine Site Dust

Control


• Wetting agents (foams and water extenders)

• Surfactants, Nonionic, Anionic, Cationic.

Application

• Dosing spray systems for foam generation on belt

feeds, 1:500

• Water extender 1:500 to 1:5000

Origin

• Surfactant manufacturing synthetic.

• Organic (palm oil) derivative

Managing fugitive dust.

Implementing control practices in open areas.

Open areas and stock piles.

Second largest dust generation source.

Open and Non Trafficable Areas

Managing fugitive dust.

Implementing control practices in open areas.

Open areas and stock piles



• Veneering



• Veneering



• Veneering water waste example



• Port Kembla



• Veneering



• Veneering



• Veneering



• Veneering



• Veneering equipment



• Veneering


• Managing fugitive dust.

• DEM Dust Extinction Moisture.

• Managing water conditioning.

• Flow properties

• Crushing circuit

• Legal constraints shipping, and contract crushing.

• Additives

• Ion exchange

• Air Entrainment free falling materials

Materials Handling


• DEM Dust Extinction Moisture

Materials Handling



Materials Handling



Materials Handling



Materials Handling



Materials Handling



• DEM under control

Materials Handling



• DEM under control

Materials Handling



• Injection opportunities

• Mechanical action

• In pit manual application or irrigation

• ROM water carts.

• Crusher plant

Materials Handling



Materials Handling


• Fog systems

Materials Handling


• Fog systems

Materials Handling

http://www.google.com.au/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=NFmXyq926ifnwM&tbnid=UkQYAOI7QMzpsM:&ved=0CAUQjRw&url=http://bkbdustsuppression.com/dust-control-2/dust-control/&ei=E_qJUYWNOcXtkgWZsoHgAg&bvm=bv.46226182,d.dGI&psig=AFQjCNHCP2VPKQY_O9QoZ3x7emX7-_Z17g&ust=1368083004140736


• Fog systems

Materials Handling


• Fog systems

Materials Handling


• Fog systems

Materials Handling


• Fog systems

Materials Handling

Spray and Fogging Systems

• Mist Curtain efficiency (droplet size and localized

environmental considerations)

• PSD and dust concentration, water to particle

mass.

• Inertia and Momentum of dust particles, wind

velocity.

• Nozzle, water quality, filtration, maintenance

• Droplet Size distribution

• Inertia and droplet momentum

• Balancing of droplets with particle–air mix

• Plant layout dimensions

• Humidity

Materials Handling


• Fog systems

• Design

• Water quality

• Build

• Install

• Commission, nozzle sizing

• Train, Maintenance.

• Parts

• Measure water flow

• Place fog close to dust generation point

Materials Handling

Contractor services

• How much service will depend on the dust

management team?

• On site application and equipment

• Separation of application services, product

supply and environmental monitoring.

• Gearing up the local contactors

• Recording abatement strategy's.

• Worksheet samples

• Area mapping

• Equipment design and installation

Contractor Services

Contractor Services

MINING COMPANY ABC

A.B.N. ***********

Minutes of Meeting

Mining area XYZ Dust Management

Held 04-Dec-12

ATTENDANCE Attendance

Julia Gillard (0429388388) Mine Present Tony Abbott Contractor Present Wayne Swan Mine Present Sarah Hanson young Enviro Absent Mason Trouchet Rainstorm Present Bob Carr Mine Absent Mason Trouchet Rainstorm Present Joe Hocking Contactor Present Malcom Turnbill Contactor Absent Craig Thomson Contactor Apology Peter Slipper Vistor Apology

File located at :

OBJECTIVE:

To review current conditions and plan dust controls for coming week

Contractor Services OBJECTIVE:

To review current conditions and plan dust controls for coming week

1. Dust Control Inventory

Min Stock Max StockCurrent

Stock

3,000-l 50000L

30-l 30-l

3,100-l 23000l

300-m3 3500

250-m3 500

5

hectacres

3

hectacr

2. Equipment Availability

374

230

4. Weather Trends

5-Dec 6-Dec 7-Dec 8-Dec

Wed Thu Fri Satmoderate high moderat

32 hot south westerly

to 30k/h

westerly

to

southerl

y to

Mining CO Custom Web Site(logon & password required)Bureau of Meteorology

moderate

61%Total Sprinklers Available

TDC Healthy

TDC Healthy

27southerly to

30k/h

26

Mulcher - Side Spreading

an issue last week new truck due Wednesday

-- still issue with pump v/v

Rainstrom

Okay

TEOM ALARMS

4-Dec

moderateTue

south westerly to 35kl/hr

Water cart

Contractor Equipment

Okay

Tractor

Equipment Condition

Dust Suppression Sprinklers Total No of Sprinklers

Action

delivery due

today

Item

No Action

required

Surfactant

Road suppresant

Water (John)

No Action

required

delivery due

todayToday

Mulch

Hydromulch

Rainstorm suppresant Gluon

No Action

required

Contractor Services

5. Dust Management Scope

New and ongoing items.

Item Location Priority Who Comment progress

19 TSF 3 – sprinkler

system

HIGH Tony Abbot Extend sprinklers --

now have 2 broken in

east ==pumping eccess

off

Dozer not available

and will need to

maintain moisture

35 TSF 4 south wall MEDIUM Wayne S Mulch small patch up job to

do

45 Batters on south

side of TSF 1

MEDIUM Slipper change to new header -

waiting on

instrumentation funds

planned for 2 weeks

time

52 exposed sand MEDIUM Craig

Thomson

investigate if Rainstorm

have a product for sand

dust suppression

trial to start in 1

month

67 TSF 2 sth east MEDIUM Gluon disturbed area

68 back drain MEDIUM Julia excavate to turn ready

to clear ongoing

70 TSF 2 west wall HIGH tidy and cover area

disturbed by Rainstorm

80% comp

71 Waste disposal

area

HIGH Malcom T Consult with processing Julia to set up

meeting with

stakeholders within

the plant

72 TSF3 east HIGH ABC required to fix

capped sprinkler in

emergency dump area

79 road from TSF 2 to

TSF 3

HIGH grade and treat Rainstorm to

investigate

82 header roads TSF

2 & TSF 4

MEDIUM Tony Abbot mulch sides and over

headers start this week

83 TFS 2 exposed

beach area

MEDIUM Rainstorm cover as much as

possible with mag

cement

west end done -- east

bank to do

90 TSF 6 excavator

track

MEDIUM Dustmag

91 TSF 2 HIGH mulch areas either end

of dyke and top of TSF

east wall 50% done

92 TSF 2 HIGH Gluon sand outlet ongoing

93 TSF 4 HIGH Dustmag access road

on south side

Contractor Services

New Business

Treatment Class Description Application Rate

1 Water sprays As required

2 Dustmag 1.5 L / m2

3 Mulch, Seeding,

Mulch applied at 300-

m3 /hectare (25mm

thk layer)

Hrydromulch applied

at 1,000-t/hectare

(14mm thk layer)

4 Flooding

ROAD Water , repair shandy mixDustmag tip road

(4,500-l Waste Oil +

10,000-l Water + 40-l)

at 10,000-l/hectare ie

3,100-l Dustmag and

28-l per hectare

References:

Document NumberDescription

5814 Aggregate/ Mulch Spreading for Dust Control

62754 Dust Suppression using Sprinklers

38101 Spray Gluon For Dust Control

38065 Establishing Pasture for Dust Control

5817 Use of Dustmag as a Dust Suppressant

40584 Waste Oil Collection and Testing Procedure

5813 Maintain Mobile Irrigation Systems

38063 Dust Control Management Planning

69568 Manage Dust During Construction at Residue

56931 Residue Dust Emission Control Strategy

69584 TEOM Alarm Procedure

58016 Response to Dust Risk Rating

5816 Weekly Area Inspections and Meetings

3450 Ambient Dust Monitoring Information

Wayne to contact Morris Turnbull in regard to improved monitoring opportunities. Peter Slipper has

requested to be involved with this contact and will set a date. The attached survey of the exposed

area shows an increase to 5 hectacres due to exposed areas on the stockpile at TSF 7. Geo now

developing a set of harrows to increase dryiing. TSF 2 N/W corner where retic pipe being stacked --

requires adequate warning to traffic -- I/H today

Contractor Services

Mine Site Dust

Control

Feed batching equipment:

• Automated

Mine Site Dust

Control


• Manual batching

Mine Site Dust

Control


• Mobile

Mine Site Dust

Control


• Mobile

Mine Site Dust

Control


• Mobile

Mine Site Dust

Control


• Fixed

Mine Site Dust

Control


• Fixed

Mine Site Dust

Control


• Fixed

Contractor services

• Skill set to apply products.

• In house vs out sourced.

• Road application skill set

• Veneer application skill set

• Tools of the trade

Contractor Services

Veneering Rehabilitation.

Hydro Mulch

Hydro Seeding

• Fibres

• Binders

• Seeds

• Fertiliser

• Top Soils

• Surface Preparation

• Machinery

• Logistics

Rehabilitation and Hydroseeding


Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding



Hydro Mulch

Hydro Seeding


Mine Site Dust

Control

• Blasting

Mine Site Dust

Control

• Blasting

Mine Site Dust

Control

• References • US Department of Agriculture Forrest Service Technology program Transport system

Watershed and air management November 1999

• US Army corps “Effectiveness of dust control agents applied to tank trails and helicopter

landing zones”

• Benefits of chemical dust control technologies, D Casey Roe

• University of Wollongong P Wypych 2012 workshop.

• www.rainstorm.com.au

• www.sunhawk.com.au

• [email protected]

http://www.rainstorm.com.au/

http://www.sunhawk.com.au/

mailto:[email protected]

News & Politics

Mason Trouchet, Rainstorm Dust Control - Action to Prevent Fugitive Dust