Mason Trouchet, Rainstorm Dust Control, Practical Dust Management – A specialists’ viewpoint

Dust Control

RAINSTORM DUST CONTROL PL The Dust Control Professionals

PDX™ Ore Conditioner

Mine Site Dust Control

0

10

20

30

40

50

60

Roads Open Areas and Stockpiles Materials Handling

Percen

tage of D

ust S

ource On Site

Mine Site Area

Source of Dust Genera5on on an average Mine Site

Objectives for Dust Prevention: •  Prevent fugitive dust •  Capture or drop fugitive dust •  Manage dust control programs •  Ensure effective environmental compliance and reporting


Monitoring

Real time Dust Control Planning

Utilising live monitoring to implement

Dust Control plans

Dust Monitor Port Headland

Modelling Predicting Weather / Dust Patterns Location: Port Headland, WA Forecast. Wind Modelling. Dust Plume Modelling.


Predictive Modelling Port Headland


Monitoring Equipment 1 Mobile Equipment.

2 Monitoring Points 3 Monitoring Stations

2 1

3



Modelling Utilising weather prediction and forecasting to prevent dust generation at source.

Dust Plumes


Methods of Dust Prevention Objective: To prevent dust from becoming fugitive

01 Wet Supression: Water Carts 02 Chemical Supression: DustMag Objective: To capture or drop fugitive dust from the atmosphere 03 Mechanical Supression: Fogging


Methods of Dust Prevention

Wind Barriers & Diffusers - Natural or built Design Engineering: Plant & Process to minimise dust generation Prevention of airborne dust is the key to good dust management.


Methods of Dust Prevention Water on dust control is water lost

EVERY DROP COUNTS

Water Conserva5on Is Essen5al

Economics, Environment and Community: The Cost Benefit

ORGANIC ACIDS ELECTROCHEMICAL POLYMER STARCH CELLULOSE CLAY ADDITIVES PETROLEUM BASED


WATER ABSORBING Dustmag visualphotos.com WETTING AGENTS (WATER EXTENDER SURFACTANTS)

AGENTS: FOAMING

BINDING / AGGLOMERATING VENEERING CRUST

Methods of Dust Prevention Chemical

Considerations of use •  Water quality •  Conservation of water •  Ease of use and effectiveness to wet surface areas of

substrate material.

Advantages: •  Good short term dust suppression, assuming the dust

particles are contacted and wetted - agglomerates the surface particles.

•  Often available on site and can be inexpensive


Methods of Dust Prevention Water


Methods of Dust Prevention Water

Disadvantages. •  Unsustainable practice - no water is recycled •  Dust control short term: (2 treatments per day often) •  Can be ineffecient dust supressant •  High operating costs: water carts, water, operators •  Operational delays due to ineffective dust control •  Loss of water - environmental impact •  No DEM moisture 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 •  Applica@on @ps •  Flexible vs. Rigid •  Count the water •  Maintenance •  Cos@ng rate / m2 / frequency / cost of product


DustmagTM

v Chemical dust suppression •  Water absorbing (deliquescent / hygroscopic) •  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



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.



DustmagTM


DustmagTM


DustmagTM


DustmagTM


DustmagTM


DustmagTM


DustmagTM


Pacific Environment - REX Dust Monitoring Mobile Sampling •  Fast characterisa5on of a large number of roads •  Easy way to determine rela5ve emissions •  Easy iden5fica5on of “hotspots” •  Calcula5on of control efficiency to test range of products

Real-‐5me PM10

GPS mapping

Temperature, pressure, flow


REX Dust Monitoring 4 circuits of a mine site during changing conditions & operations

Uncontrolled Sec5on


REX Dust Monitoring Hotspots Modelling: Air particulate concentrations (PM10)


Reducing Water Usage on a 50km Haul Road Water Versus DustMag

Comparison : Water Treatment versus DustMag: Haul Road 50km x 27m width =

Total Area 1,350,000m2

Daily Water Use 5.4 million litres / day

Timeframe – 6 months

0 1 2 6 5 4 3

Daily Water Treatment : 4 litres / m2

DustMag Water Usage 1 litre / m2 / once per 3 months


Water Usage 50km Haul Road: Water Versus DustMag

0

20,000,000

40,000,000

60,000,000

80,000,000

100,000,000

120,000,000

140,000,000

160,000,000

180,000,000

Month 1 Month 2 Month 3 Month 4 Month 5 Month 6

Volume of W

ater U

sage / M

onth (Litres)

Water Treatment (6 Months)

50km Haul Road: Water Only Use (Red) versus DustMag Water Use (Blue)

Water Treatment

DustMag Treatment

Total Water Use over a 6 month period 985,478,400 Litres Total DustMag Water Use 2,700,000 Litres Total Water Saving with DustMag 982,778,400 Litres


Applica@on @ps

•  Evaluate what applica@on program will fit with your workplace environment.

•  Top down surface applica@on •  Pavement mix. •  Applica@on frequency •  Compac@on •  Road condi@on during applica@on •  Rain events

v Chemical dust suppression •  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


v Chemical dust suppression •  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 applica@on •  Pavement mix. •  Applica@on frequency •  Compac@on •  Road condi@on during applica@on •  Rain event •  Maintenance to Rigid pavements


Polymag Paczyme


Polymag Paczyme Be[a We[

v Chemical dust suppression •  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.


v Chemical dust suppression •  Electrochemical Derivatives •  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.


v Chemical dust suppression •  Electrochemical Derivatives •  Paczyme Organic

Origin •  Enzymes, ionic products, sulphonated oils,

ammonium chloride. Environmental Impact •  Need specific product analysis. •  Some products highly acidic in concentrated,

undiluted form.


v Chemical dust suppression •  Wetting agents (foams and water extenders) •  Surfactants “Betta Wett” “Polymag” Attributes •  Concentrated format. •  Extends water penetration. •  Slows evaporation, compactable additive to polymer

applications. •  Foaming formulations. Limitations •  Limited life span.


v Chemical dust suppression •  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

Open and Non Trafficable Areas

Managing fugitive dust. Implementing control practices in open areas. Open areas and stock piles


Open areas and stock piles •  Veneering




Open areas and stock piles •  Veneering water waste example











Veneering


Veneering

Open areas and stock piles •  Veneering equipment


Rail Car Veneering


•  Managing fugitive dust. •  DEM Dust Extinction Moisture. •  Managing water conditioning. •  Flow properties •  Crushing circuit •  Legal constraints shipping, and contract crushing. •  Additives •  Ion exchange •  Surfactants •  Foaming surfactants •  Agglomeration organic formulations. •  Air Entrainment free falling materials

Materials Handling


Managing Fugitive Dust Water versus PDX: Dust Extinction Moisture Content (DEMC)

Dust Ex5nc5on Moisture (DEM) Water 7.8% DEM Dust Ex5nc5on Moisture (DEM) PDX 6% DEM

Dust Air Par@culates (PM10)

Ore Moisture (% by Mass)

4% 6% 7% 8% 9% 10% 5% 1

100

50 25 10

1000

4.5%

PDX: 6% DEM

Water

PDX

WATER: 7.8% DEM


Ore – Improving Flow & Productivity By reducing Dust Extinction Moisture

Flow

Dust Ex5nc5on Moisture Content (DEMC) %wb

3% 9% 12% 15% 18% 21% 23% 6%

2

10

8

6

4

~12 – 18 No Flow Water Only

No Flow Starts to Slurry ~18%

When Ore is at high moisture no flow un@l forms slurry

Water

PDX

•  Managing fugitive dust. •  DEMC Dust Extinction Moisture Content

Materials Handling

•  Managing fugitive dust. •  DEM Dust Extinction Moisture

Materials Handling


Materials Handling

•  Managing fugitive dust. •  DEM Dust Extinction Moisture under control : PDX

Materials Handling

•  Managing fugitive dust. •  DEM Dust Extinction Moisture •  DEM under control

Materials Handling


Materials Handling

•  Managing fugitive dust. •  DEM Dust Extinction Moisture •  Injection opportunities •  Mechanical action •  In pit manual application or irrigation •  ROM water carts. •  Crusher plant

Materials Handling

•  Managing fugitive dust. •  Fog systems

Materials Handling


Materials Handling


Materials Handling


Materials Handling


Materials Handling


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

•  Managing fugitive dust. •  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 Trends5-Dec 6-Dec 7-Dec 8-DecWed Thu Fri Sat

moderate high moderat32 hot

south westerly to 30k/h

westerly to

southerly 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 ScopeNew 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 area68 back drain MEDIUM Julia excavate to turn ready

to clear ongoing70 TSF 2 west wall HIGH tidy and cover area

disturbed by Rainstorm80% 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 ongoing93 TSF 4 HIGH Dustmag access road

on south side

Contractor Services New Business

Treatment Class Description Application Rate1 Water sprays As required2 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 Sprinklers38101 Spray Gluon For Dust Control38065 Establishing Pasture for Dust Control5817 Use of Dustmag as a Dust Suppressant40584 Waste Oil Collection and Testing Procedure5813 Maintain Mobile Irrigation Systems38063 Dust Control Management Planning69568 Manage Dust During Construction at Residue56931 Residue Dust Emission Control Strategy69584 TEOM Alarm Procedure58016 Response to Dust Risk Rating5816 Weekly Area Inspections and Meetings3450 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

Feed batching equipment: •  Automated


Feed batching equipment: •  Manual batching


Feed batching equipment: •  Mobile






Feed batching equipment: •  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















References •  US Department of Agriculture Forrest Service Technology Program &

Transport System Watershed and Air Management, November 1999 •  US Army Research:

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.

Mason Trouchet M. 0429 388 777

[email protected]

www.rainstorm.com.au www.sunhawk.com.au


Mason Trouchet, Rainstorm Dust Control, Practical Dust Management – A specialists’ viewpoint

Engineering

applica onfrequency compac

deliquescent hygroscopic

review current conditions

feed batching equipment

managing fugitive dust

plan dust controls

implementing control practices

extends water penetration