Dust has a negative effect on employees, the company and the environment and can lead to serious consequences and increased costs if dust problems are not addressed properly and in time.
There are a number of different dust control solutions depending on operating conditions, dust source, the need for a fixed or mobile installation, access to water, etc. To make sure we deliver an optimal and sustainable solution, we recommend a site visit early on in the project, where we jointly look at the dust problem, discuss specific requirements and investment objectives.
How does dust control with water mist work?
The most important factor for effective dust control is the water mist. Its function is to wet the airborne dust particles, which become heavier and fall to the ground. At the same time, the water mist moistens surfaces (material as well as the ground), which prevents dust particles from becoming airborne. The amount of water mist is adjusted to avoid water accumulating on the ground or make the material too wet.
Right droplet size
It is important that the droplets in the water mist are the right size. If the droplet is too large and moves too fast in relation to the dust particle, the dust will not be bound. A smaller droplet moves more slowly and binds the dust much more effectively. Conventional irrigation systems usually create large, heavy droplets, which means that the dust is not bound effectively.
Different types of dust require different sizes of water mist droplets to achieve optimal results. EmiControls' advanced valve technology allows the machines to create water droplets in the range of 10 to 100 µm (ideal for dust control) and the equipment can be configured according to type of dust and operating conditions.
Optimal water mist amount and distribution
Is the dust mostly airborne? Should the material in the process or on the ground be soaked preventively to avoid the dust becoming airborne at a later stage? The right amount of water and distribution of the water mist is important to achieve a good result and effective dust control.
The amount of dust in the air is measured in mg/m³. Together with our supplier EmiControls, we have extensive knowledge and experience in determining the amount of water per cubic metre needed to acheive effective control dust in different environments.
Dimensioning and choosing the right solution
Every dust problem is unique. To ensure the most effective dust control, it is important to understand how different parameters affect the choice of product and type of solution.
Indoors or outdoors
Factors that need to be considered for indoor or outdoor dust control include temperature, wind and amount of water required to effectively control the dust.
If dust control is carried out where there is a risk of sub-zero temperatures, the system needs to be equipped with a heating kit. The equipment can then operate in temperatures down to -10°C. In more extreme conditions, the unique V22Orca dust controller works in temperatures down to -45°C.
Wind and other air turbulence, such as moving machinery, can affect results. It is therefore important to consider where and how the equipment is placed, as well as choosing the most suitable type of equipment.
If the wind often blows from a particular direction, a fixed installation may be a preferred option. However, if the wind direction changes frequently, it may be advisable to choose equipment that can easily be moved around in order to make the dust control as effective as possible. Wind impact can also be reduced by placing the system close to the dust source.
Amount of water
Adding too much water can be a problem, both indoors and outdoors. It can lead to a possible safety risk due to ice formation, or the material being handled becoming too wet. Therefore, it is very important that the system is dimensioned to suit specific site conditions, and to be able to control the amount of water as needed.
Dust problems at one specific point or over a larger area
When choosing dust control equipment it is important to know if the dust problem area is at a specific point or over a larger area.
If the dust problem is at a specific point, dust is usually suppressed close to the dust source, e.g. at transfer points, tipping points or crushers. Recommended equipment would be a mobile lance (L3) or a near-source system consisting of H2 components or DustFlex.
When there is a dust problem over a larger area, dust controllers (V7, V12S, V22) are more suitable and can cover a distance up to 90 metres.
Fixed or mobile installation
What type of work is carried out at the site and what does it look like in the area near the actual dust source? Wind impact? Machinery, personnel and vehicles in motion? Other possible safety hazards?
Type of installation and location of the equipment is important to consider in order to achieve an optimal result. For example, if the dust source is at a specific point, a fixed installation is usually most suitable. In some businesses, the dust source is constantly moved and a mobile solution will be the right choice.
Dust controllers can be equipped with different types of undercarriages to suit a specific business activity or location. For example, a dust controller can be placed on a lift to avoid it being in the way of machinery and personnel. A trailer can be the best option in order to easily move equipment around the site, depending on where the dust control needs are.
Is electricity and water available at the site?
When electricity or water is not available in the area where dust suppression is to be carried out, a mobile solution with a water tank and/or a generator is a good solution.
Typical applications for a mobile solution with a generator and a water tank are construction sites, demolition work, quarries, open-pit mines, or any other application with no access to electricity and water or if it is difficult and costly to supply.
System monitoring and control
Factors to consider when choosing a control system include equipment accessibility during operation and workplace safety. In many cases, automated control and monitoring of the entire system using CURT Management software can save costs and increase safety.
Manual control via a control panel
The equipment can easily be controlled manually via the very user-friendly control panel, see video.
A remote control can be a good option when, for example, it may be difficult to access the equipment during operation or purely for safety reasons.
The remote control:
- is very user-friendly with distinct symbols on the buttons
- has a large emergency button
- a lost remote control can easily be replaced with a new one by using an ID key
- comes with a protective case
CURT - Automated monitoring and control
CURT is a management software that monitors all dust suppression equipment and controls the entire system in real time.
At sites where operations regularly generate dust, information (such as weather, amount of dust in the air, and time) can be used to automatically determine when the system should be in operation and how it should be controlled.
There are many benefits. It means, for example, that staff do not have to be out on site as much - switching equipment on and off. It is also a safety issue. Automated monitoring and control leads to further cost savings as the system is only running when there is a need for dust control.
Project review and proposed solution
To deliver the optimal solution, it is important to go through in detail various factors that affect product choice, type of solution, investment objective, and other requirements at an early stage of the project.
A start-up meeting is important to find out about various factors that will affect choice of equipment and solution in order to achieve the most efficient and sustainable solution. We are happy to set up the start-up meeting as a web meeting or a site visit, depending on your preference. All details and information from the start-up meeting we will summarise and go through with you to make sure we agree on project scope and objective.
Next step, we present a proposed solution, focusing on function, lifespan, quality, choice of material, operating and maintenance costs, and environmental impact. Our goal is to deliver a sustainable solution that creates added value to your company,