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<<< Back to Dust Control Handbook for Minerals Processing Printin

Chapter 2: Preventing Dust Formation

For problems with accessibility in using figures and illustrations in this document,
please contact the Directorate of Science, Technology and Medicine at (202) 693-2300.

Introduction

In any minerals processing facility, dust is generated when ore is shattered or broken as in dumping,
transferring, or handling. Proper design, selection, and operation of equipment to minimize ore breakage c
reduce dust.

Two primary groups of equipment are used in minerals processing operations:

Processing equipment such as crushers, screens, grinding mills, and dryers
Bulk material handling equipment such as belt conveyors, screw conveyors, bucket elevators, feede
hoppers

Processing equipment processes the ore into a final product. Bulk material handling equipment transfers
processing equipment and from the mine to the processing facility.

Processing equipment must be retrofitted with dust control measures; dust control measures can be implem
bulk material handling equipment is designed. Although the choice of equipment for a specific operation
process needs, the use of alternate equipment, improved equipment design, or sometimes even a chang
can greatly reduce dust emissions. Simple measures such as providing shrouds, covers, or enclosures ar
source can also help to contain dust emissions or allow the existing dust control system to operate more

The following sections describe the most commonly used processing and bulk material handling equipmen
dust emission points, and measures to prevent or reduce dust generation, emission, and dispersion. Seve
minerals processing operations are also discussed.

Belt Conveyors

The belt conveyor is one of the major pieces of equipment used to transfer ore between processing equipm
one point to another within a minerals processing facility. It is also one of the most frequent sources of dus
 Types of Belt Conveyors

There are two primary types of belt conveyors:

Troughed belt conveyors
Flat belt conveyors

Troughed belt conveyors are the most common type of conveyor used in mining and minerals processing
Flat belt conveyors are used mostly in non-mining industries.

Emission Points

Pelt conveyors emit dust from the following four points:

The tail end, where material is received
The conveyor skirting
The return idlers, due to carry-back of fine dust no the return belt
The head end, where material is discharged

The following measures should be considered in the design or selection of a belt conveyor.

Dust Prevention Measures

Belt Loading

The amount of dust generated at belt conveyor transfer points depends on the way the material is loaded
To reduce dust generation-

The material should be loaded onto the center of the belt.

The material and the belt should travel in the same direction and at the same speed, whenever pos

Impact at Loading Point

A momentary deflection of the belt between two adjacent idlers may result when ore strikes the belt. As a
of dust may leak out under the skirting rubber seal. To prevent dust emissions at the loading point, adequ
impact idlers (1-ft centers) should be located at transfer points. These will absorb the force of impact an
deflection of the belt between the idlers, thus preventing dust leakage under the rubber seal.
 Conveyor Skirting

Skirtboards are used to keep the material on the belt after it leaves the loading chute. They are equippe
rubber strips that provide a dust seal between the skirtboards and the moving belt.

The conventional skirtboard design uses vertical rubber strips. This design is not recommended for the
reasons:
The vertical rubber seals wear out quickly.
The rubber must be adjusted constantly to prevent dust leakage, and this is often neglected.

Illustrated is an improved skirting design, which has the following important features:
The skirtboards are sufficiently high and wide to accommodate both the volume of material and the
surges caused by the inflowing material and induced air.
Quick-disconnect clamps are used instead of conventional bolts for fast, easy adjustment of the rub
The flexibility of the inclined skirting rubber allows it to rest on the moving belt at all times, even wh
is momentarily deflected between idlers.
The inclined skirting rubber is 1/2 in. thick with 60-65 durometer hardness and provides a greater w
increased life.
The top edges of the skirtboards are covered and sealed with a self-adhesive neoprene rubber gask
proper dust seal.

A double skirting can be installed in the impact zone if the incoming material hits the skirting rubber direct
the wear rate.

Muckshelves

Muckshelves can be installed in the belt conveyor's material impact zone to-
 Load the material centrally on the belt and keep the belt properly aligned
Protect the inclined skirting rubber from direct impact with the incoming material

Dust Curtains

Dust curtains are used to contain dust within a conveyor enclosure. They should be installed at the head,
ends. Dust curtains are made of rubber with 60-65 durometer hardness and can be hinged at the conveyo
exit ends to provide easy access during maintenance.

Belt Cleaners

Belt Scrapers - A belt scraper should be installed at the head pulley to dislodge fine dust particles that m
the belt surface and to reduce carryback of fine materials on the return belt. A scrapings chute should also
to redirect the material removed by the belt scraper into the process stream or container.

V-Plow - Product spillage or dust leakage may fall on the non carrying side of the belt and eventually bu
surfaces of the tail pulley. This buildup may move the belt laterally and thus make the skirting rubber sea
A V-plow installed on the non-carrying side of the belt will clean the belt and prevent buildup of material an
tail pulley, thus keeping the belt properly aligned.

b=Belt Width (in.) A B C

24 19 18 6
30 24 21 8
36 29 27 9
42 36 32 11
48 41 36 12

Conveyor Capacity

The belt conveyor should be designed to operate at 7% of its full rated capacity. This reduces spillage, du
 and wear on skirting rubber seals.

The following measures are suggested to adjust the loading capacity of existing conveyors:
Increase the belt speed
Change the idlers' angle (for example, from 20 to 35 )
Increase the conveyor width (for example, from 24 to 36 in.)

Transfer Chutes

Transfer chutes transport ore from one piece of equipment to another. Significant dust generation can re
transfer chute is not designed properly.

Dust Prevention Measures

The following points should be considered when designing a transfer chute:

The chute should be big enough to avoid jamming of material and reduce air flow. When fine materi
are mixed in the product stream, the chute depth should be at least three times the maximum lump
jamming.
The chute should be designed so the material falls on the sloping bottom of the chute and not on th
equipment.
Wherever possible, the material should fall on a local rockbox or stonebox rather than on the metal

- Reduce dust and noise generation

- Absorb the impact of incoming material

- Reduce wear and abrasion of the chute surfaces

- Reduce the height of material fall

- Reduce dust emission from the backspill rubber seal at the tail end of the conveyor

Note: When handling fine or abrasive materials, a number of small steel angles can be welded on the chu
form mini-rockboxes. The oncoming material slides on the material stored in the rockboxes, greatly reduci
abrasion of the chute bottom.
Abrupt changes of direction must be avoided to reduce the possibility of material buildup, material
dust generation.
Curved, perforated, or grizzly chute bottoms should be used when the product stream consists of fin
lumps. Placing a layer of fines ahead of the lumps on the belt helps prevent heavy impact of mater
belt, which reduces belt wear and dust generation.

Other types of chutes are used for controlling dust during bulk material handling:
Spiral chutes are used to prevent breakage of fragile or soft material.
Bin-lowering chutes are used to feed bins and hoppers without generating large amounts of dust. T
consist of a channel that runs from the discharging equipment down into the bin. The channel is sec
 sloping side of the bin. Ore slides down the chute quietly, with minimum dusting. When the materia
big side or the surface of the material in the bin, it leaves the chute from the sides and spreads out
Rock ladders are used to prevent breaking and crumbling of rock. They consist of a steel tower with
baffles (or mini-rockboxes) arranged so the discharged rock never has a free drop of more than 5 to
lower drop height significantly reduces dust.
Telescopic chutes are used to minimize the height of material fall into stockpiles. The telescopic sec
usually cable-connected so a winch can lift the sections of the chute. The lower end of the chute is a
just clear of the top of the stockpile to reduce dust.

Enclosures

Enclosures are used to contain dust emissions around a dust source. They can also lower the exhaust
requirements of a dust collection system or help make the existing dust collection system work more e

The following guidelines are suggested when designing an enclosure for a dust source:
Enclosures should be spacious enough to permit internal circulation of the dust-laden air.
Enclosures should be arranged in removable sections for easy maintenance.
A hinged access door should be provided to aid routine inspection and maintenance.
Dust curtains should be installed at the open ends of the enclosures to contain dust and reduce air

Crushers

Crushers reduce coarse material to a desired size. The crushing process uses mechanical energy and rubbi
the rock. The forces applied to rock fragments during crushing processes are-
Compression force
Impact Force

Compression is a slow application of force on the rock while impact is a short, sudden application of

All crushers generate dust. Crushers that primarily use impact forces produce large amounts of fines and
that primarily use compression forces produce dust in proportion to the stage of reduction: dust productio
progressively from first- to third-stage crushing.

Types of Crushers
 There are six main categories of crushers used in minerals processing operations:
Jaw crushers
Gyratory crushers
Cone crushers
Hammermills
Impact breakers
Roll crushers

Jaw, gyratory, and cone crushers primarily use compression forces; hammermills, impact breakers, and roll
impact forces.

Emission Points

Crushers emit dust primarily from two points:

Crusher discharge
Crusher feed

Dust Prevention Measures

Dust control measures are not usually considered in the design of a crusher. However, the use of shrouds o
for crushers can contain the dust so that a dust control system can operate more efficiently. The following
recommended:
A crusher feedbox with a minimum number of openings should be installed. Rubber curtains should
minimize dust escape and air flow.
The crusher should be choke fed to reduce air entrainment and dust emission.

Dust escape at the crusher discharge end can be minimized by properly designed and installed transfe

Screens

Screens are used to sort material according to size. The material fed into a screen is separated into a leas
Undersize material, which passes through the screen opening
 Oversize material, which is retained on the screen surface

Although screening can be either wet or dry, dry screening is most often used in minerals processing o

Dust is generated in all dry screening processes. However, the amount of dust depends on the particle size
the ore, the moisture content, and the type of screening equipment used. Generally, a screen processing fi
produces more dust. Also, screens agitated harder and faster produce more dust than those vibrated mor
slowly.

Types of Screens

The four most common types of screening equipment are-

Grizzlies
Shaking screens
Vibrating screens
Revolving screens

Emission Points

In general, screens emit dust from the following points:

The top one-third of the screen surface where incoming material hits

The openings between moving parts (the screen) and stationary parts (the discharge chutes)

Discharge chutes

Dust Prevention Measures

The rate of dust generated by screens cannot be altered. However, properly enclosing the screen can re
emissions. A complete enclosure that can be easily removed for maintenance and inspection should be
commercially available enclosure system consists of a special rubber cloth, rubber molding, and simple me
The rubber cloth can be attached to the screen to provide an almost perfect dust seal between the scre
discharge chutes. The top of the screen can also be enclosed by the rubber cloth to prevent dust escap
lightweight rubber covers not only provide a dust-tight enclosure but also allow easy maintenance, inspe
replacement of screening surfaces.

A tight sealing system reduces dust emissions and also minimizes air flow, which reduces the exhaust vo
dust collection system installed downstream.

Some screen manufacturers provide sheet-metal covers to enclose the top of the screen. These covers a
when properly maintained. However, they do not provide a dust seal between the moving screen surfac
stationary chutes.

Storage Bins and Hoppers

 Bins and hoppers are used to store ore temporarily. They act as bufers to absorb the surge between unl
consumption.

The ore is fed into the bin by various equipment, such as conveyors, elevators, and screens. The materia
discharged from bins and hoppers through gravity or vibrating feeders.

Emission Points

Bins and hoppers primarily emit dust from-

Feed openings
Discharge feeder
Inspection doors

Dust Prevention Measures

Dust emissions during feeding operations can be minimized by-

Installing a bin-lowering chute.
Completely enclosing the bin or hopper. When bins and hoppers are enclosed completely, an inspec
bin-level detector should be installed so the material level can be monitored.

Dust emissions during material discharge can be minimized by-

Installing a telescopic chute.
Installing a loading spout.

Such spouts are sophisticated versions of the telescopic chute and are used to load and stack ore into bag
railroad cars. The spouts apply three basic principles of dust control:

1. Containment

2. Dust capture close to the source

3. Preventing air flow caused by the falling material

The falling material is enclosed by a flexible duct, acting as a chute, which retracts as the height of the m
increases. The duct also prevents air flow during free fall of material between the chute and stockpile. Th
dust is captured by the same flexible duct and is conveyed, countercurrent tot he material flow, to a dus

Another method commonly used to reduce dust emission is to transfer dusty air through a vent into an ad
silo. Of course, this assumes that multiple bins are used, that the bins are totally enclosed, and that the a
has room for the displaced air to expand.
 Bucket Elevators

A typical bucket elevator consists of a series of buckets mounted on a chain or belt that operates over he
wheels. A steel casing usually encloses the entire assembly. The buckets are loaded by scooping up mate
boot (bottom) or by feeding material into the buckets. Material is discharged as the bucket passes over the

Types of Bucket Elevators

Centrifugal discharge
Positive discharge
Continuous discharge

Emission Points

Pucket elevators emit dust from two points:

The boot, where material is fed
The head wheel, where material is discharged

Dust Prevention Measures

The steel casing that encloses the buckets and chain assembly contains dust efectively unless there ar
openings in the casing.

Emissions at the boot of the bucket elevator can be reduced by proper design of a transfer chute between
equipment and the elevator. Dust production can be reduced significantly by keeping the height of mate
minimum and by gently loading material into the boot of the elevator.

Proper venting to a dust collector, as well as proper enclosures and chutes between the elevator dischar
 receiving equipment, will control dust emission at the discharge end of the bucket elevator.

Feeders

Feeders are relatively short conveyors used to deliver a controlled rate of ore to the processing equi

Although dust is emitted from all types of feeders, the amount of dust depends on-
The kind of material being handled
The size of material
The degree of agitation of the material

Types of Feeders
Apron
Belt
Reciprocating
Vibrating
Disc

Emission Points

Dust emission points from a feeder are-

At the tail end, where material is received
At the head end, where material is discharged

Dust Prevention Measures

Reduce dust production during feeding operations by-

Enclosing feeders as much as possible
Selecting an oversize feeder or a feeder that produces less agitation of the ore

Screw Conveyors

Screw conveyors are one of the oldest and simplest types of equipment used to move ore. They consist o
screw rotating in a stationary trough. Material placed in the trough is moved along its length by rotation o

Emission Points

Screw conveyors emit dust primarily from-

 The inlet, where material is received
Leaks in the trough cover
Worn-out troughs

Dust Prevention Measures

Normally, screw conveyors are totally enclosed except at the ends, where emissions can be controlled by p
chute design.

The trough cover is usually fastened by nuts and bolts. However, to maintain a proper dust seal, a self-
neoprene rubber gasket should be installed. Many manufacturers provide two-bar flanges and formed-ch
members that make a continuous pocket around the trough. The flange-cover sections are set in this chan
channel section is filled with dust, an efective dust seal is created.

Abrasive materials can wear out screw conveyor troughs quickly unless a special coating or abrasion-resis
is used for the trough.

Pneumatic Conveyors

Pneumatic conveyors are tubes or ducts through which material is moved by pressure or vacuum (suction

Pressure systems can be either high or low pressure. Low-pressure systems operate at pressures obtainab
high-pressure systems use a compressed-air source. When material is fed into a pressure system, the a
immediately suspends is and conveys it to a cyclone- or filter-type collector. The conveying air then escape
cyclone vent or a filter.

Vacuum systems ofer clean, efficient pickup of material from rail cars, trucks, or bins and hoppers for un
other types of equipment. Cyclone receivers or filters are used at the end of such systems to separate th

Emission Points

Since pneumatic systems are totally enclosed, dust emissions do not usually occur unless the system ha
areas.

Dust Prevention Measures

Because maximum wear in the conveying ductwork occurs at elbows, long radius elbows made of heavy ga
should be used. The elbows can also be lined with refractory or ceramic material to further reduce the war

In low-pressure pneumatic systems, dust may leak through joints. Self-adhesive neoprene gaskets should b
 joints to provide a dust-tight seal.

Grinding Mills

Grinding and pulverizing reduce ore to a desired fineness for further treatment.

In its basic form, a grinding mill consists of a horizontal, slow-speed, rotating cylindrical drum. Rod, pebb
mills are the most common types of grinding mills used in minerals processing operations. Steel rods, ball
roll freely inside the drum during rotation to provide the grinding action.

Emission Points

Dust is emitted from a grinding mill-

At the inlet, where material is fed
At the outlet, where material is discharged

Dust Prevention Measures

Most grinding mills are fed by a belt conveyor or a feeder. The ground ore is discharged to a screen, con
elevator.

Properly designed enclosures and chutes, as well as rubber dust seals between moving and stationary co
should be installed at the feed and discharge ends to minimize dust emiss

Dryers

Dryers remove water or other volatile material from solid substances primarily b
hot gases into a drying chamber. The hot air readily absorbs moisture from th

Rotary dryers, flash dryers, spray dryers, and tray and compartment dryers are
many types of dryers. However, in minerals processing operations, rotary dryers
commonly used.

Rotary dryers consist of a horizontally inclined rotating cylinder. Material is fed at

discharged at the other end. In direct-type rotary dryers, hot gases move through the cylinder in direct con
material, either with or against the direction of its flow. The cylinder is equipped with flights, which lift the
shower it down through the hot gas stream. This type of dryer has a potential for high levels of dust emi
indirect-type rotary dryer, heat is applied by combustion gases on the outside of the cylinder or through s
inside the cylinder. This type of dryer has much less tendency to emit dust. It is usually used when continu
powdery or fine material is needed.

Emission Points

Dust emission can be a problem in any dryer in which material is agitate or stirred. Dust is emitted only
discharge end.

A study on rotary dryers by the Barber Greene Company concluded that the dust carryout increased propo
the square of the exhaust gas volume.
 Dust Prevention Measures

The hot, dust-laden gases from the dryer are carried to a dust collector, and dust normally does not escap
ventilation system is work out or improperly maintained.

Stockpiles

Large volumes of processed material are stored in open or enclosed stockpiles. Open stockpiles are norma
the material size is large. Enclosed stockpiles are used when material is either very fine or must be st
Stockpiles are considered active when material is continuously removed or added. They are considered in
material is not added or withdrawn for long periods. All types of stockpiles can be significant dust s

Emission Points

Generation of dust emissions from stockpiles is due to-

The formation of new stockpiles
Wind erosion of previously formed piles

During formation of stockpiles by conveyors, dust is generated by wind blowing across the stream of falling
separating fine from coarse particles. Additional dust is generated when the material hits the stock

Dust Prevention Measures

Dust from stockpiles can be reduced through the following measures:

Minimizing height of free fall of material and providing wind protection using-

- Stone ladders, which consist of a section of vertical pipe into which stone is discharged from
conveyor. At diferent levels, the pipe has square or rectangular openings through which the
flows to form the stockpile. In addition to reducing the height of free fall of material, stone l
provide protection against wind.

- Telescopic chutes, in which the material is discharged to a retractable chute. As the height
stockpile increases or decreases, the chute is raised or lowered accordingly. Although some
material from the end of the chute to the top of the stockpile occurs, proper design of the ch
the drop to a minimum.

- Stacker conveyors, which operate on the same principle as telescopic chutes. The conveyo
adjustable hinged boom that raises or lowers it according to the height of the stockpile.

Minimizing wind erosion of the stockpile by-

 - Locating stockpiles behind natural or manufactured windbreaks

- Locating the working area on the leeward side of the active piles

- Covering inactive piles with tarps or other inexpensive materials

Minimizing vehicle traffic on or around the stockpile

Using specialized equipment such as a reclaimer to minimize the disturbance of the stockpile or pro
tunnel underneath to reclaim the material.

Haul Roads

Haul roads are used in minerals processing operations to transport ore from the quarry to the processing p
as within the facility. Large amounts of dust can be generated during this process.

Emission Points

Dust emissions from hauling operations vary, depending on-

The condition of the road surface
The volume and speed of vehicle traffic

Dust Prevention Measures

Dust emissions from haul roads can be minimized by-

Spraying the soil frequently with water, chemicals, oil, or other stabilizing agents
Paving the haul roads (Note: Paved roads should be cleaned and vacuumed periodically to remove a
soil and dust.)
Reducing traffic volume by replacing small haul vehicles with larger ones.
Reducing and strictly enforcing traffic speed

Truck and Railroad Car Dumping

Ore is dumped or unloaded from trucks or railroad cars in most minerals processing facilities.

Emission Points

Dust generation and emission during the dumping of ore are caused by-
Dumping large volumes of material in a relatively short time (3 to 10 seconds), which displaces an e
of air carrying fine dust particles
Wind spreading the dust

Dust Prevention Measures

Enclosures should be used to contain dust during dumping. A sufficiently large enclosure will contain most
as well as aid internal recirculation of the dust-laden air.

Enclosures for railroad- car dumping operations must have openings at each end to allow cars to enter
However, these openings can crate a wind-tunnel efect. To minimize this efect, the size of these opening
kept as small as possible with shrouds, rubber curtains, etc. Shrouds or rubber curtains should also be us
 types of enclosures to reduce the area through which air can escape or enter.

In addition to the above design guidelines, the following operational measures are suggested:
Increase the amount of open area through which the material flows. This measure will reduce the es
through unused areas.
Decrease the amount of open area through which the material flows. This measure will reduce the e
through unused areas.

Power Handling and Packing

Pulverized material, such as sand, silica flour, hydrated lime, or other powdery material, is normally shipp
bulk quantities through truck or railroad cars or in small volumes using paper bags, drums, or barrels. Al
process of filling a bag, drum, or barrel is simple, packing fine material can be an extremely dusty op

Two types of mini-bulk-packing processes commonly used in minerals processing are-

Bagging
Barrel or drum filling

Bagging

This process uses bagging machines commonly known as packers. Several diferent types of packers, such
auger or screw type, belt or sling type, drop type, and impeller type, are available. However, the two mos
used packers in the minerals processing industry are-
Open-mouth (drop-type) packers using sewn or adhesive-sealed bags
Spout fluidizing packers used with seal-valve bags

The open-mouth type uses gravity to fill sewn or adhesive-sealed bags. The material is fed into a weigh h
when the correct weight is reached, the feed gate closes and the contents drop into the open-mout

The spout fluidizing packer uses compressed air to force the material through a nozzle into a paper bag eq
seal valve. When the desired weight is reached, the compressed air supply is cut of and the feed stopped.
pressure of the contents of the bag then forces the valve to close.

Barrel or Drum Filling

Sometimes the final product is shipped in barrels, drums, or containers. The material is fed into the rece
gravity.
 Emission Points

Considerable amounts of dust may be emitted during bagging operations. The following are common oc
Dust emitted while filling the bag. Material and dust spillage may occur because of the compre
to pressurize the bag.
Bag surface dust. The dust emitted during bagging extremely fine products may stick to the oute
the bag. This dust may become airborne during later handling, conveying, loading, or stacking of ba
Unfortunately, attempts to clean the bags by air brushing have been unsuccessful.
Poor bag quality. Poor bag quality or improper storage may result in broken bags, leaky valves, or
seams. Leaks from the valve and poorly glued seams may be continuous source of dust as the bag
from the bagging machine to the loading point.
Spillage from nozzles. Spillage from the nozzle of spout fluidizing packers is another major dust s
bag is usually discharged from the machine immediately after the flow of product into the bag is sto
However, fluidized material remaining in the nozzle area continues to discharge, which results in sp
spillage may also prevent the bag valve from sealing properly, which may cause another dust sourc
is handled.

Dust generation and emission during barrel- or drum- filling operations result primarily from-
Displaced air carrying fine dust
Spillage of material during the filling process and subsequent handling of drums and barrels

Dust Prevention Measures

Dust emissions caused by bagging machines can be minimized in the following ways:
The bag should be properly attached to the spout to reduce dust leakage or material spillage.
Where possible, the bag's outer surfaces should be wetted to prevent the surface dust from becomi

Dust emissions due to poor bag quality can be minimized by

Following proper bag specifications
Eliminating sharp obstructions during bag-handling processes
Using proper compressed-air pressures to fill the bag, which can significantly reduce the number of
Storing bags at recommended temperatures and humidity levels to prevent drying and cracking

In the case of spout fluidizing packers, the following additional measures are suggested:
The fluidized air in the bag should be vented to control dust emissions during filling. This can be don
bags with perforations staggered through the layers of bag paper. This eliminates a direct path for t
and reduces dust spillage, while maintaining adequate air relief through the bag. The porosity of the
further aids air relief and has a filtering efect.
The nozzle should be cleaned before the bag is released from the machine to prevent spillage of ma
the nozzle. Cleaning is accomplished by injecting a short, high-velocity, low-volume blast of compre
the rear of the nozzle to fluidize the remaining material in the nozzle and force it into the bag. (This
useful only for fine granular material, such as whole grain sand. For finely ground material such as g
a specialized nozzle developed by the Bureau of Mines may be used.)
Dust generation and emission during drum or barrel-filling operations can be minimized by-
Providing a cover with a flexible chute attached to the storage bin
Enclosing the operation as much as possible to contain the dust
Reducing the rate of discharge of the material
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