Good recommendations, proven performance and an unmatched record for fast, efficient grain handling led Subic Bay Freeport Grain Terminal Services Inc to opt for a Siwertell unloader. Since its delivery, feedback has been resoundingly positive, with the unloader meeting the company’s growing capacity demands.

Customer need

Located within the Subic Bay Freeport terminal on the west coast of Luzon, in the Philippines, Subic Bay Freeport Grain Terminal Services Inc handles various grains, including a third of all wheat imported into the country. In the past, this has amounted to around 1.2 million metric tons of wheat per year and until recently it met this demand using three low-capacity rail-mounted grab bucket unloaders and several mobile pneumatic units.

However, grain intake at the port has been increasing steadily, and Subic Grain expects this to rise at around five percent each year for the next few years on the basis of guarantees from its customers.

With a major responsibility to the people of the Philippines, Subic Grain began to investigate a means of improving its capacity in line with the rising expectations of importers. It also wanted to achieve this in an efficient, environmentally friendly way. Furthermore, aside from grain, the company needed a dry bulk material handling system that could unload cement, in line with its long-term development plans.

Our solution

Subic Grain decided on a Siwertell ST 490-F ship unloader, which was installed in 2019 on an existing quay alongside the buckets, grabs and pneumatics. The unloader is now being used to serve the Philippines’ growing trade in wheat imports, discharging vessels up to 50,000 dwt at rated capacities of 600t/h for grain, and will comfortably be able to switch to handling cement at rates of 800t/h.

Expansion plans at Subic Bay are far from over, with plans for a new dedicated grain unloading quay. But for the time being, the installation on the existing quay is allowing Subic Grain to benefit from its investment as quickly as possible.

“Aside from being cost efficient relative to the market, Siwertell unloaders came with very good recommendations from some of our friends from within the grain industry and friends from different sectors altogether,” said  Carlo Eduardo D Aliño, Subic Grain Vice President, Operations and Business Development. “Based on their feedback, Siwertell unloaders did indeed deliver all; efficient discharge operations, heavy-duty fortitude, as well as long-term reliability and usage. We expect to be in touch for our next unloader(s) soon.”

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Bruks Siwertell has completed the delivery of two high-capacity Siwertell 790 D-type unloaders. Ordered to ensure zero dust emissions and spillage-free coal handling, they now operate as a critical part of a large expansion project at the 3,800MW coal-fired Suizhong Power Plant in Liaoning, China.

“Seaside resorts and large coal handling facilities are not natural companions, but busy ports, space constraints and growing populations often require them to be, and when they are, some of the strictest environmental regulations come into force,” says Per Wahlström, Bruks Siwertell Contract Manager for the Suizhong project.

This was the issue faced by Suizhong Power Plant when it needed to expand. Located on the Bohai Sea, Liaoning is the most populous province in the region and its seaside resorts are particularly popular holiday destinations for people living in Beijing.

“No spillage or dust emissions from handling coal were allowed,” continues Mr Wahlström. “This is where Bruks Siwertell came in. The power facility approached us to see if our enclosed unloaders would meet the standards required, and they do.”

The initial contract was signed with Suizhong Power Generation Co Ltd and Shenhua in 2016. Since then, Shenhua has merged with another large Chinese energy company, Guodian; forming China Energy. The combined energy group owns one other smaller Siwertell unloader, which was delivered in 2018 to the Suqian power plant, formerly part of Guodian.

“Suizhong needed to increase its annual intake of coal to around six million metric tons in the most environmentally friendly way possible,” Mr Wahlström explains. “Previously, the coal was handled with grab cranes, and in comparison, our unloaders offered significantly higher rates of through-ship efficiency, environmental protection, shorter turnaround times for vessels, and cost savings.”

The two units ensure totally enclosed, dust-free coal handling and each offer a continuous rated capacity of 1,500t/h, serving vessels up to 50,000 dwt. They were delivered at the end of 2019 to accommodate the owner’s extended construction schedule and were transported fully assembled on a barge from Nantong.

“The most critical phases were loading and unloading the completely assembled units from the barge onto the power station’s new jetty using a floating crane. Safety precautions, effective preparation and good communication involving all parties are crucial in these operations,” he notes.

The jetty extends 2,500m out into the Bohai Sea and accommodates the unloaders on a 300m-berth along with transfer towers and new conveyors.

“The customer was very happy to receive the equipment and eager to put it into use,” says Mr Wahlström. “The unloaders have now been in service for a few months and early feedback on their performance is positive.”

Siwertell unloaders are known for their reliable, long service, particularly enhanced with good maintenance regimes; keeping the unloaders in peak condition is now being discussed with their new owners.

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Features Tier IV Final Gen Set

(Peoria, Ill.) – A global innovator in dust and odor control technology has updated its family of self-powered dust suppression equipment with Tier IV Final-compliant generators, ensuring compliance in all 50 states.  BossTek made the announcement with the debut of the new DustBoss^® DB-60 Fusion^TM, a field-proven suppression system driven by a high-reliability 25 HP electric motor and paired with a gen set powered by a heavy-duty 4-cycle indirect injection diesel engine.  Designed, engineered and assembled in the USA, the generator features a dual-containment fuel cell, heavy gauge lockable enclosure and oversized brushless alternator for easy starting.

Permanently mounted on a rugged road-worthy trailer, the company’s Fusion lineup is proving to be a popular and effective means of delivering versatile, mobile dust suppression technology to sites that lack a readily available power source.  The company expects to unveil two other Fusion models in early 2019, giving customers the ability to select the size and coverage range needed to best suit their operations.

The new generator series is designed with sound attenuation for excellent noise reduction and a multi-voltage switch with utility power outlet in all voltage modes.  The digital engine / generator controller is equipped with single button stop / start and an 80-gallon fuel capacity, giving the units a run time of more than 24 hours at a prime rating of 45 kVa.  Like its previous Fusion systems, BossTek warrantees the DB-60 Fusion for three years / 3,000 hours, with 5-year / 5,000 coverage on the electric motor and a 2-year / 2,000 hour warranty on the generator.

What Tier IV Means

Tier 4 refers to the latest emission milestone established by the U.S. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB).  The regulations apply to new engines found in off-road equipment, including construction, mining and agricultural equipment, as well as marine vessels, locomotives and stationary engines used in industrial and power generation applications.

Tier IV-compliant engines are designed to significantly reduce emissions of particulate matter (PM) and oxides of nitrogen (NOx) to near zero levels.  Relative to previous emissions standards, Tier IV-compliant engines reduce emissions by over 95 percent for most agricultural and construction equipment and just over 86 percent for much larger applications such as locomotives and marine vessels.  The Tier 4 emission standards are roughly similar to emission reduction requirements for engines that power heavy-duty trucks.

How It Works

The DB-60 Fusion drives pressurized water through a circular stainless steel manifold with 30 atomizing spray nozzles, then launches millions of tiny droplets with a powerful fan that produces 30,000 CFM (849.50 CMM) of air flow.  Atomized mist droplets of 50 to 200 microns in size are thrown out in a 200 foot (60 meter) cone at an adjustable 0 to 50° elevation angle, capturing airborne dust particles and dragging them to the ground.  Unlike industrial sprinklers used for the same purpose, which can require hundreds of gallons of water per minute, the DB-60 only uses about 23 GPM (87 LPM) to help avoid pooling or runoff.

A touch screen panel for controlling the dust suppression unit is encased in a NEMA 3R cabinet, allowing operators to control oscillation, booster pump, fan and water.  The cabinet is constructed for outdoor use, designed to provide protection against solid foreign objects (such as dirt), air (dust, emissions), water (rain, sleet, snow) and ice formation.  The system provides valuable mobility and versatility in one of the most popular and effective dust suppression designs on the market, able to deliver up to 62,800 square feet (5,834 square meters) of coverage.

“Maintaining air quality is essential for communities near a demolition project, mining operation or other bulk material handling activities, but even in places with little infrastructure, dust can choke worksites and foul equipment,” said Project Engineer Jason Lesch.  “We engineered the Fusion to be highly mobile, with its own power source, so it can be easily towed anywhere on a job site.”

Equipped with an in-line 75 mesh, 200 micron filter, the unit can be specified with special filtration to accommodate non-potable water sources.  In addition, the new design can be optimized with a Variable Frequency Drive (VFD) to precisely adjust fan speed.  An optional dosing pump is available for precise metering of additives to enhance particle control even further.

BossTek is a global leader in solutions for dust suppression, odor control and crowd cooling, serving a wide range of applications.  The company’s high-quality, industrial strength equipment carries a no-excuses guarantee of customer satisfaction.  For more information, visit contact BossTek.

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A wholly-owned subsidiary of CVR Partners LP, the facility produces about 388,900 tons of ammonia and 963,700 tons of UAN each year.  One of the primary issues Operations Technical Superintendent Marc Gilbertson wanted to address was material containment, to reduce the amount of dust and spillage that escaped from conveyors 19A and 19B, each 300 feet long with a 24-inch wide belt.  Travelling at 400 FPM (~2 MPS), the belts carry an estimated 1400 TPD (3080 kilos) of petcoke to an entrained flow gasifier.

“We were seeing waist-deep piles accumulating each day, which required an average of about 90 man-hours per week to safely clean,” Gilbertson explained.  In addition, the operation invested another 16 hours of equipment maintenance time each week.

Stabilizing and Sealing

The company’s proposal included upgrading both 19A and 19B transfer points to eliminate belt sag, provide effective sealing and improve belt cleaning, as well as alignment systems to deliver continuous adjustment and maintain a consistent belt path.  Technicians first installed three Martin^® Impact Cradles, located under the belt in the loading zones.  The cradle design features a bed of steel angles lined by energy-absorbing impact bars with a top layer of low friction, ultra-high molecular weight (UHMW) plastic.

After the impact zone, a series of 16 slider cradles were installed on each conveyor to stabilize the belt line and eliminate bounce.  Designed for conveyor speeds up to 700 fpm (3.5 m/sec) and belt lengths of more than 50 feet (15.2 m), the units offer a flat and stable belt surface throughout the settling zone, reducing fugitive material and extending belt life.

Following the cradles, 20 Trac-Mount™ Idlers were installed on each conveyor.  These rugged idlers have sliding frames on a stationary base that fits in tight spaces between belt support cradles for easy installation and service.

Dust Management

The system upgrade also included 90 feet of modular chute wall.  The pre-fabricated components make it easy to design and install transfer points and stilling zones to manage air flow and keep airborne dust inside.  The components simply bolt together to reduce installation labor and replacement time.

To further improve containment, the Martin technicians also installed 184 feet of the company’s ApronSeal™ Skirting System, which provides dual-seal efficiency with a single, one-piece sealing strip to prevent the escape of fines and dust.  It incorporates a primary seal clamped to the steel skirtboard to keep lumps on the belt and a secondary or “outrigger” strip to capture any fines or dust particles.

Tracking

The mis-tracking belt issue was addressed with a Martin Tracker™ system to deliver immediate, precise adjustment of wandering belts.  Utilizing innovative multiple-pivot, torque-multiplying technology, it detects slight misalignments initiated by unbalanced loads and fouled rollers, using the force of the belt to immediately adjust its position and realign the path.  The tracker keeps the belt in alignment with automatic corrections to reduce edge damage, prevent spillage and maintain belt health.

Carryback

To address the issue of carryback, technicians installed a two-stage belt cleaning system.  The primary unit is the QC1™ Cleaner HD blade.  Engineered for head pulley diameters from 12-24 inches (~305-600 mm), the QC1 HD is suited for belts from 18-96 inches wide (~400-2400 mm) and speeds up to 900 FPM (4.6 m/sec).  The unit’s patented “CARP” Constant Angle Radial Pressure design maintains cleaning performance through all stages of blade life, and the rugged 3/8-in. (95 mm) steel tubing main frame holds the cleaner snugly in place.

Mounted directly after the primary cleaner, the Martin SQC2S™ secondary cleaner features individually cushioned tungsten carbide blades for effective cleaning without risk to the belt or splices.  Patented rubber buffers maintain the cleaning pressure throughout blade life.  Like the QC1, blade removal and replacement is a simple operation by removing the lock pin and sliding out the cartridge.

Results

Plant officials are extremely pleased with the outcome, which has drastically reduced the amount of dust and spillage, and with it the unproductive labor time to deal with the

consequences.  Gilbertson estimated that the total maintenance time to manage fugitive material on both conveyors is now down to about eight hours per week, with belts and other components no longer showing signs of premature wear.  In addition to the estimated $14,000 USD per month labor savings, longer service life from belts and components are expected to further increase the benefit.  Moreover, company personnel spend less time working in close proximity to the moving conveyor, reducing potential risk, and the manpower savings can be applied to more productive activities.

“We’re very happy with the results,” Gilbertson said.  “What used to be a huge maintenance task is now just occasional sweeping.”  The Coffeyville facility is already considering proposals to upgrade additional conveyors, as well as future training and service agreements.

The post Conveyor Upgrades Improve Efficiency, Material Containment and Safety appeared first on Cargo Connexion.

The Martin^® Roll Gen™ System is designed to create a self-contained mini power station that allows operators to run electrical monitoring systems, safety devices and a variety of other components.  Able to be retrofitted on existing idler support structures, the generator can be employed on virtually any steel roller.  The device is considered a significant step toward eliminating power production obstacles, as conveyors move into the next generation of “smart systems” that are predicted to be more sustainable and autonomous.

“Running auxiliary power can be both complicated and costly, requiring expensive labor and oversized cables to accommodate the inevitable voltage drop over long runs, as well as transformers, conduit, junction boxes and other components,” commented Andrew Timmerman, Product Development Engineer at Martin Engineering.  “And using even a small conventional generator to provide power introduces a different set of issues, including flammable fuels.”

The Long Ride

Conveyor #107-1 is the longest outdoor conveyor system on the Illinois Cement site, running 600 feet (182 m) and discharging either onto the #107-2 stack-out conveyor or the 250-foot-long (75 meter) belt leading directly into the plant, based upon immediate production needs.  It’s a 30-inch wide (762 mm) mechanically-spliced belt with a 35º trough that travels at ~400 fpm (2 mps), conveying nearly 300 st/h (272 mt/h) of limestone.

Material arriving from the quarry can be either wet, dry and dusty or anything in between, depending on the season and weather.  The changing work environment presented challenges throughout the entire conveying system, with different weather conditions triggering various types of carryback.  Cleanup was labor-intensive.

“The primary cleaner blades we had in place wore quickly, causing spillage that required us to take personnel from other areas to clean the buildup,” explained Illinois Cement Maintenance Planner Brian Brandner.  “We were out there cleaning or adjusting the tension to minimize spillage a few times a week.  When it got really cold, we wouldn’t have as many issues with dust or carryback, but the frost accumulation required us to keep the belt running at all times, which lowered the blade life and caused undue wear on the belt.”

Phase one of the Martin Engineering solution involved placing a “smart” dust suppression system at the transfer point between the 153 and 107-1 conveyors.  Phase two included an automated, pneumatically-tensioned belt cleaner and air cannon system at 107-1’s discharge zone.  Both components are powered by the Roll Gen System.

To manage the dust, technicians installed a Martin^® Surfactant Dust System at the transfer point between 153 and 170-1 to deliver a chemically-enhanced water spray as a topical treatment for material at the point of emission.  Triggered by a sensor as soon as the load enters the transfer point, the system supports dust mitigation measures already in place to minimize the labor needed for maintenance and replacement of the dust collector cartridges.

Cleaning the Belt

Close to the mid-point of the system, conveyor 107-1 begins a gradual 20-foot (6 m) rise and discharges into the transfer chute leading either to the stack-out conveyor feeding the storage area or the main conveyor entering the plant.  At that transfer point, technicians installed a Martin^® QC1™ Primary Cleaner XHD (extra heavy duty) tensioned with an Automated Blade System (ABS).

Connected to a small 24V DC air compressor and a control panel powered by the Roll Gen, the ABS pneumatic tensioner delivers precise monitoring and tensioning to reduce the labor typically required to maintain optimum blade pressure through manual adjustment.  Equipped with sensors to confirm when the belt is running empty, the system automatically backs the blade away, minimizing unnecessary wear to both the belt and cleaner.  Upon detection of an empty belt, the system is set to run for one full belt rotation to clean the surface thoroughly before pulling away.  The result is consistently correct blade tension with reduced power demand on start-up, all managed without operator intervention.

“The new cleaner has been a game changer when it comes to the amount of maintenance, equipment wear and manpower for cleanup,” Brandner pointed out.  “The blade is no longer just scraping an empty belt, which has extended its operational life and minimized wear to the belt face and splice.”

Transfer Chute Flow

While monitoring the results of the installation, Martin Engineering technicians observed that the decreased spillage resulted in a proportional increase in fines discharged down the transfer chute.  Exposed to the outside environment, the chute began to form significant buildup along the sides, at the diverter gate and on the internal shelf meant to slow the flow of material.  The technicians had a solution to this unexpected result, and to mitigate the buildup, they installed a Martin^® Hurricane Air Cannon.

“When there’s cargo flowing, the cannon fires about every ten minutes, which keeps fines from clinging to the walls and promotes proper flow,” Brandner said.  “If the material is extra wet and building up faster than usual, we can just go over and fire it manually at any time.”

Results

The use of multiple technologies working in tandem to control material flow and prevent fugitive particles has dramatically improved the material handling system’s efficiency.  The modifications have helped Illinois Cement reduce labor and equipment expenses, considerably cutting the manpower needed to clean spillage along the conveyor path.  The result is a cleaner, safer and more productive operation.

“The entire project has been a success, particularly in how many man-hours we save in maintenance and upkeep,” Brandner concluded.  “The tensioning system does a great job, and the Roll Gen puts out enough power that we’re considering adding an automated secondary cleaner and a vibrating dribble chute to capture even more carry-back.

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The disadvantage of this system compared to traditional pneumatic unloaders is the cost. With a normal pneumatic unloader the pipe hangs on a flexible joint.  With a Flexiport the forces created to loosen the material must be absorbed by the structure. The result is a vertical truss system and reinforcement throughout the structure.  A simple system adapted from pneumatic unloaders can help to make bigger holes in the material but cannot increase the efficiency much.

The Flexiport was primary designed in the 70’s to bring a solution for meal discharging at feed mills. The capacity was low and normally a fixed unloader design.

In 2002 with biomass use introduced at power plants for co-burning with coal, Neuero supplied a machine for Essent energy at Gertruidenberg in The Netherlands. This machine was designed to unload every biomass listed from wood pellets to wood chips, wood pieces from demolition, palm pit kernel and even ONF (organic natural fraction) which in essence is dust, light material with a free density lower than 0,2t/m3. Low noise levels was required because of a nature park at the other side of the Amer River.  The goal of one ship per shift of 8 hours was achieved. Tests show an average of 70% during the entire ship unloading operation. Later the installation was upgraded from 600 to 800m3/h.

In 2013 the company Marine Harvest / Graintec had the need to use the Flexiport to unload Fishmeal and variety of meals In Norway, Bergen. The good result of the Flexiport reflected in an order for a second unloader for a similar installation to be delivered in Scotland by mid-2018.

Stiving to meet and exceed client expactations, new developments for higher capacities are planned.

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Siwertell, part of Bruks Siwertell Group, has secured an order for a ship loading system from Irish mining company, Boliden Tara Mines DAC; an operating subsidiary of Boliden AB. The specially-designed system will serve the company’s new terminal located in Dublin Port’s Alexandra Basin, ensuring close to zero dust emissions for the operator. The order was booked into Bruks Siwertell Group’s second quarter order intake.

“Boliden required a flexible system capable of handling a variety of cargoes and a wide range of vessel sizes, but with a very strict approach to dust emissions,” explains Peter Göransson, Sales Manager and Senior Advisor, Siwertell. “Our lengthy experience and expertise in bulk material loading was a significant factor in winning this contract, including the fact that no efforts were spared in designing a triple-enclosed loading system that will ensure as close to zero emissions as technologically possible for the operator.

“A high loading capacity, combined with easy system operation and low service and maintenance costs, were also significant factors in Boliden’s decision to invest in Siwertell’s market-leading technology. Additionally, it complies with best available technology (BAT) and reference document (BREF) regulations,” adds Mr Göransson.

The new system comprises a triple-enclosed belt-type ship loader, with luffing and slewing capabilities, a reversible shuttle-belt conveyor with dual remotely-operated connection points, as well as a triple-enclosed jetty and overland conveyor.

It will handle zinc and lead concentrates, which are transferred from rail wagons to a receiving storage building. From here, a conveyor belt leads to a new quayside facility  in Alexandra Basin. Siwertell designs are well-suited for sticky and hard-to-handle materials and the new system will be capable of loading ships of up to 10,000 dwt at a continuous rated capacity of 600t/h.

“Based on Siwertell designs, and with production and construction supervision as a part of the delivery scope, Siwertell, together with local partners, will have full control of the project from design to handover,” continues Mr Göransson. “With carefully-selected components from Swedish and other European sub-contractors, we will deliver an efficient, reliable, high-performance system with low operational and maintenance costs.”

The steel structures for the ship loader will be produced in Far East and equipment will be mainly supplied from Sweden. The overland and jetty conveyor will be produced locally in Ireland with the conveyor equipment supplied from Europe. The system will be erected and commissioned at Dublin Port in partnership with an expert Irish company and is expected to be fully operational by August 2019.

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[Coeymans, NY] — A leader in dust control solutions has helped a port located along the Hudson River control fugitive particle emissions at the dock and in the industrial park using atomized mist technology.  The Port of Coeymans employs two DustBoss^® DB-60™ atomized mist cannons from BossTek^® for dust suppression in a variety of activities and applications.  One machine is mobile, used to control particle emissions during the unloading and storage of bulk materials.  The other is tower-mounted to suppress particulates at the metal scrap yard.  This provides operators the versatility to address surface suppression and airborne control at different areas of the port, resulting in a drastic reduction in fugitive dust.

About 40-50 vessels per year arrive from Greece, Turkey, Egypt and Spain, delivering nearly 33,000 tons (30,000 metric tons) per week of clinker, a dry chalky substance used as a binder in cement products.  When the ship arrives, large clamshell shovels controlled by tower cranes unload the material from the ship’s cargo hold, over the ship’s deck — from 25 (7.5 meters) to as high as 120 feet (to 36.5 meters) in the air — to a 20-foot-tall (6 meter) hopper, which discharges into a 40-ton (36 metric ton) haul truck.  The truck drives the material the short distance to the adjacent industrial park, where it is stored for further transport.

“The most dust was produced when the substance was dropped into the hopper, and although it has a bag house attached, a percentage would still escape,” explained Stephen Kelly, Vice President of Sales and Business Development at the Port of Coeymans.  “We realized that we also needed dust suppression for scrap metal storage and other operations in the industrial park.  Our goal was to improve air quality for the safety of our employees and the surrounding community.”

The 300-foot (91.4 m) wide dock receives vessels of up to 750 feet (228.6 m) in length overall (LOA).  With no beam restrictions, it accepts ships with a draft (depth) of 31 feet (9.4 m).  In addition, a 300-foot (91.4m) by 60-foot (18.3 m) inlet channel with a 15 foot (4.5 m) draft allows loading/unloading from both sides.

Like many other facilities handling bulk materials, the Port of Coeymans limits fugitive dust emissions by employing a couple of simple methods.  One is limiting the distance the dust-emitting cargo travels from the ship’s hold to the dock.  This is done by using a clamshell shovel suspended from a crane to slowly unload the material into a tall portable hopper with a baghouse dust collection system.

To further mitigate dust, crane operators reduce the amount of material collected by the shovel.  Although this extends the unloading time, it curbs the amount of material escaping from the top or sides of the shovel and thus further limits dust emissions.

Another area that needed dust suppression was in the industrial park.  Located about 700 feet (213 m) inland from the Hudson River with no natural wind barrier, the surface is a combination of concrete, packed earth and gravel.  Scrap metal from various sources (demolition projects, old cars, dismantled ships, etc.) is transferred from barges and deposited into storage piles.  During windy conditions, the unprocessed metal can emit dust both during offloading from vessels and loading onto ground transport.

The industrial park also stores mounds of various raw commodities.  These well-organized piles, stretching as high as 20 feet (6 meters), are exposed to outdoor conditions and can emit dust in moderate winds, during offloading by haulers, disruption by front loaders and loading into trains or trucks.  Additionally, this heavy ground equipment can kick up its own dust during normal operations.

Kelly contacted BossTek , manufacturer of the DustBoss series of industrial atomized mist cannons and decided to rent two of the mid-sized DB-60 units to test them out.  Mounted on a heavy-duty wheeled carriage with a pintle hitch, the DB-60 has a specially designed barrel with a powerful fan on the back end and a circular manifold with 30 atomizing spray nozzles on the front.  The fan forces air through the cannon and past the manifold, launching millions of tiny atomized mist droplets 50 to 200 microns in size.

By introducing droplets roughly the same size as the dust particles, the droplets are able to travel with the particles, collide with them and drag them to the ground before they drift onto the dock area or across the site line.

A 25 HP fan producing 30,000 CFM (849.50 CMM) of air flow propels the engineered mist in a 200-foot (60 meter) long cone that reaches high over the deck of the ship.  This type of coverage offers simultaneous surface suppression to material in the cargo hold and airborne suppression through the shovel’s path from the hold to the hopper.

Approximately the height and length of a standard golf cart and weighing around 1,800 lbs. (816 k), the unit is easily moved on its wheeled carriage by a pickup truck or fork lift from the port to the industrial park.  There, operators can cover more than 125,000 square feet (11,613 square meters) of the storage and traffic area using the 359º degree oscillation.  The Port of Coeymans uses municipal water through a hose with a cam-and-groove quick disconnect coupling leading to a booster pump that raises the pressure up to 160 PSI (11.03 BAR), with a maximum of 250 PSI (17.23 BAR).  The unit only requires a constant supply pressure of 10 PSI (.069 BAR), and when a non-potable water source is used the DB-60 can be equipped with an in-line 30 mesh, 595-micron filter system.

There are some clear benefits over the use of hoses, which are required to be manned and can use up to 100 gpm (378 lpm).  The DB-60 uses far less water (only 26.7 gpm /101.1 lpm), delivering a much larger coverage area and requiring no labor for ongoing operation.  Workers at the port simply place it in the desired location, point it in the right direction, hook up the hose and power, turn it on and walk away.

Result

Operators report that air quality at the port has significantly improved during the unloading of clinker and other dusty materials, and that fugitive dust emissions have not been seen leaving the site since adding the units to the facility’s dust management plan.  The cannons are easily positioned on the dock, taking up little room and covering a large area, allowing crane operators to transfer material from hold to hopper more efficiently.  The industrial park has experienced a noticeable improvement in air quality, especially when a DB-60 is in operation during dry and windy periods.

“We are very happy with how the DustBoss controls the dust, how heavy-duty it is and how it works every time we turn it on,” Kelly concluded.  “BossTek has been very responsive and great to work with.  I would recommend their atomized mist machines to any of my colleagues.”

BossTek is a global leader in dust and odor control solutions for the storage and handling of clinker, petcoke, coal, rock and aggregate, as well as controlling air quality during port unloading, recycling and scrap processing, mining, earth moving and construction demolition.  The company’s DustBoss product line utilizes atomized mist technology propelled by powerful fans to capture fugitive particles over a wide area.

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[Neponset, IL] – In a move to help all silica dust-producing operations comply with impending rule changes, two pioneers in industrial dust control are reminding customers that the Occupational Safety and Health Administration (OSHA) respirable crystalline silica (RCS) dust emissions Final Rule [OSHA §1910.1000 Respirable crystalline silica] compliance deadline for general industry and maritime is June 23, 2018.  Both experts in complementary technologies covering a broad range of activities, Martin Engineering and BossTek (formerly Dust Control Technology) help operators safeguard the health of individuals through the use of field-proven equipment to minimize fine particulates, forced downtime and potential litigation.

Serving customers from mining, aggregates and coal handling to demolition, workplace safety has always been a priority for the sister companies.  “We believe dust control doesn’t need to come at the expense of production or profits, but should support operations and deliver a return on investment,” explained Jerad Heitzler, Foundations™ Training Manager at Martin Engineering.  “Although added regulations are always a strain on any business, compliance is an opportunity to assess aging systems and improve efficiency.”

Why the Regulation?

Due to the small size, RCS of PM₁₀ (particulate matter ≤10 microns [μm]) can penetrate the body’s natural defenses (mucus membranes, cilia, etc.), reaching deep into the lungs.  Invisible to the naked eye and able to travel long distances on ambient air currents, workers are often unaware of lingering RCS and take off protective masks, risking exposure and potentially contracting silicosis over time.

Silicosis is a chronic and irreparable disease that affects millions of workers in a wide variety of industries.  Without proper protection, workers with extensive exposure can experience a buildup of RCS deep in the lungs, restricting lung capacity.  Silicosis can potentially lead to more harmful and life-threatening lung ailments such as pneumonia, pulmonary tuberculosis and lung cancer.

With this in mind, not only does the Final Rule require regular monitoring by the employer, but it also sets personal exposure limits (PEL) and suggests engineering controls and particulate isolation rather than putting the entire onus of wearing uncomfortable respirators on the employees.  By doing this, regulators also limit fugitive dust emissions from leaving the site line and exposing the wider public.

“The RCS regulations are touching a wide range of companies,” said Edwin Peterson, CEO of BossTek.  “Some operations can implement a single solution, whereas others create dust throughout the entire process and require unique solutions at each stage.”

Being Compliant

Companies are required to follow OSHA’s rules of compliance by using a personal dust monitor worn by a trained employee to monitor the amount of RCS and determine whether the exposure is under the average “action level” of 25 µg/m³ (micrograms of RCS per cubic meter of air).  Plants must protect workers if they have an amount of RCS dust above the PEL of 50 µg/m³, averaged over an 8-hour day.  To control these levels, OSHA provides guidelines regarding methods of compliance, advising companies to:

• Use engineering controls – These include isolating dust in sealed chute systems and dust collectors, and/or using water-based atomized suppression systems.
• Provide respirators – Compliance cannot be achieved by respirators alone, but respirators must be provided for use in areas where engineering controls cannot adequately limit exposure.
• Limit worker access to high exposure areas – Limit access to areas where workers could be exposed to dust concentrations above the PEL.
• Develop a written exposure control plan – Have it available along with monitoring results.
• Offer medical exams to highly exposed workers – Review the regulation for compliance details.
• Train workers on silica risks and how to limit exposures – Workers should be able to identify to OSHA inspectors the dust control supervisor and the compliance details when asked.

Non-compliance could result in fines, process disruptions and legal action by federal or state agencies or workers.  If PEL readings are at or above the permissible exposure level, plants must take action with isolation or engineered controls.  And fines for first offences can be steep.  For example, following the construction industry deadline of June, 23^rd 2017, some general contractors and developers faced fines of $40K- $70K.

Isolation and Engineering Controls

Isolation to control dust exposure entails enclosing a conveyor system through the material transfer and sealing in particles to help prevent them from escaping.  On a fast moving, high volume operation, air flow through the settling zone should be controlled to minimize its escape.  An effective transfer zone slows the air down, allowing the material and dust time to settle.  New modular structures deliver the versatility to adapt to virtually any material transfer, enabling the construction of a transfer chute and settling zone of varying heights and lengths to meet specific needs.  Specially-configured dust curtains can also be installed to promote settling, and top-mounted dust bags release excess air while capturing particles that remain in the air stream.

For heavy duty applications with short ducting runs that exceed the volume of a dust bag, an integrated air cleaner is a compact dust collector located directly above the conveyor transfer point.  It captures agitated dust in a filter, then uses a reverse pulse of air to return particles to the main cargo stream.

The system is not sealed if the chute skirting doesn’t maintain constant contact with the belt.  Mounted on the outside of the chute with optional quick release clamps for safer access and maintenance, innovative apron seals provide a dual-seal to further reduce the escape of fines and dust.  The patented design features a secondary sealing strip that rides the belt to offer an extra layer of protection against dust emissions and spillage.

For hydrophobic materials, engineering controls such as spray systems can apply dust-suppressing surfactant and crusting agents using strategically placed nozzles and a fully automated control system to avoid waste.  Able to be placed almost anywhere within the cargo stream from loading to discharge, the sprayed surfactant agents reduce the surface tension of water, improving its ability to wet surfaces and form fine droplets that reduce dust emissions.

Another concern operators should be aware of is carryback.  Without thorough discharge of bulk materials from the head pulley, fines can stick to the belt or get caught in cracks and divots, dropping off randomly and potentially creating fugitive dust along the entire return path.  Having the proper primary and secondary cleaners is key to reducing carryback.  For extra cleaning of tacky or powdery cargo, operators may consider installing a Washbox Cleaning System consisting of a powder-coated steel enclosure equipped with rollers, spray bars, inspection doors and secondary cleaners.

Outdoor Emissions

To address outdoor dust emissions from storage pile management to crushing and recycling activities, atomized mist cannons use high-pressure water driven to a circular manifold at the end of a specialized cylindrical barrel with an industrial fan in back.  As the unit oscillates, the fan directs air through the cone-shaped cannon and propels millions of tiny droplets approximately the same size as the dust particles in a long cone covering an area up to 5 football fields in size.

For stackout conveyors and chutes where the cargo stream is exposed to open air currents and wind, point source suppression such as non-mechanical misting rings and spray bars are designed to control dust emissions.  A misting ring encloses the stream in a curtain of atomized mist, containing it within the material flow.  Open-air discharge resulting in dusty blowback from impact — e.g. when vehicles load into a hopper or from a conveyor discharging into a transfer chute — can be suppressed by misting bars and sprayers, which create a dust barrier.  Like the spray systems mentioned above, these technologies can also be bolstered by surfactants for even more effective suppression.

“Compliance not only protects workers, but also protects the bottom line from fines, downtime and lawsuits,” said Peterson.  “Investing in long-lasting and field-proven equipment translates to a sensible ROI and peace of mind over the long term.”

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Unlike its larger siblings, water is supplied to the DB-30 Fusion by a standard 5/8″ (15.8 mm) garden hose, so it can be used at any location with a working hose bib.  Equipped with an in-line 75 mesh, 200 micron filter, the unit can also be specified with special filtration to accommodate non-potable water sources.

With an adjustable throw angle from 0-50 degrees of elevation and a range of approximately 30 meters (100 feet) in calm conditions, the standard configuration includes user-definable 359 degree oscillation, allowing the unit to cover as much as 31,000 square feet (2880 square meters) with a powerful dust-trapping mist.  The new design can also be optimized with a Variable Frequency Drive (VFD) to precisely adjust fan speed.  An optional dosing pump is available for precise metering of additives to even further enhance particle control.

The extremely water-efficient design consumes just 2.5 gallons per minute.  That’s compared to competing dust control methods such as manual spraying that can use hundreds of gallons per minute, resulting in over-saturation, run-off concerns and higher water costs.

A touch screen panel for controlling the DB-30 Fusion is encased in a NEMA 3R cabinet, allowing operators to control oscillation, fan and water.  The cabinet is constructed for outdoor use, designed to provide protection against solid foreign objects (such as dirt), air (dust, emissions), water (rain, sleet, snow) and ice formation.

Maintenance requirements for the new design are minimal, even though the unit carries an industry-leading 3-year/3000-hour warranty on the dust suppressor and a 2-year/2000-hour warranty on the gen set.  If potable water is being used, nozzles typically need to be inspected just once per year.  The turntable bearing on the oscillator should be greased annually or as needed for harsh service conditions and the fan motor should be lubricated every 10,000 hours.  Like any diesel engine, the gen set should have regular inspections and changing of oil, coolant and filters.

“This design was developed in response to input from the marketplace, which indicated that some customers would benefit from a more compact design that’s well-suited to smaller projects or tight spaces,” said BossTek Sales Manager Mike Lewis.  “The 7.5 HP electric motor generates 9200 CFM of air flow, and it uses the same industrial-strength construction as the larger models: a manifold with 30 specially-designed nozzles that atomize the water supply, creating droplets between 50 and 200 microns in size for maximum particle attraction.”  The company also offers a full line of surfactants, tackifiers, and odor control additives that are fully compatible with the equipment.

“We’re always developing new technologies, and we’re excited to introduce this new product design to serve our customers even better,” Lewis added. “It’s our customers, first and foremost, that drive our innovation and passion, and they will always remain our primary focus.”

BossTek is a global leader in solutions for dust suppression, odor control and crowd cooling, serving a wide range of applications. The company’s high-quality, industrial strength equipment carries a no-excuses guarantee of customer satisfaction, backed by a 3-year / 3,000-hour warranty. For more information, visit www.bosstek.com.

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