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BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 1
Dust Solution Options for theHandling, Loading & Transfer
of Bulk Materials
Peter [email protected]
10.“Prevention” Dust Generation Mechanisms (solids/air flows; particle damage; etc)
The 10 Ways to Control Dust1. General Ventilation (dilution)2. Containment (integral filtration)3. "Push–Pull" System4. Suppression (water, chemicals, additives,
foam): Total Particle or Veneer Treatment5. Mist/Dry Fogging Systems: PSD/droplet size6. Agglomeration (ionisation, ultrasonics)7. Local Exhaust Ventilation Vacuum PC8. Wind Barriers (trees)9. Vegetation
Protection
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 2
Dustiness/Dust Extinction Moisture (DEM): AS4156.6 (2000) I.S. EN15051 (2006)
Particle/Bulk Characterisation: Chemical Composition
Wettability
Moisture retention (evaporation)
Agglomeration
Flowability (handleability)
…to meet Application Requirements
…including Environment & Social Impacts
New Developments in SustainableDust Suppression Technology
© Wypych, 2013
BMEA Rotating Drum Dustiness Testers
I.S. EN15051AS4156.6
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 3
Comparison of Dustiness Tests
© Wypych, 2013
Dustiness Test Problems
Ore at 8.1% wb
(DEM = 11% wb)
Conc at 1.6% wb
(DEM = 2.8% wb)
…Possible Handling/Flow Problems!!
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 4
Mist/Dry Fogging Systems – Issues:1. Mist Curtain Efficiency (depends on product
and application requirements)…2. PSD and Dust Concentration3. Inertia and Momentum of Dust Particles and
Air (including “gusts”)4. Nozzle Design (water; air-water; impurities)5. Droplet Size Distribution6. Inertia and Momentum of Droplets7. Dynamic “Balancing” of Droplets with
Particle-Air Mixture8. Orientation (plant layout; dimensions)9. External Factors (obstructions; peak flows)
© Wypych, 2013
Video
ROM Hopper Sprays - Ineffective
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 5
Video
Solutions Workshop D
Stacker Sprays - Ineffective
© Wypych, 2013
Many dust generation processes involve free-falling materials:
PREVENTION: (1) Dust Generation andAir Entrainment Mechanisms
“Fugitive” Dust Particles
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 6
> Interstitial+ Induced+ Entrained+ Displaced
Control Volume, Q?
Entrained Air Dominant!!
© Wypych, 2013
Air Entrainment andDust Generation Research
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 7
Air Flow in Plume
Double h 220% increase
Double h 60% increase
Exp/New Theory Q h5/3:
CEMA Model Q h2/3:
© Wypych, 2013
Other Case Studies(free-falling materials)
Truck Dump Train Dump
Stacker ROM Hopper
Rotary CarDumper 1
Rotary CarDumper 2
Loader
….Other Examples Workshop D
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 8
© Wypych, 2013
Case Studies
P1
P26 m/s
Chute P = P2 – P1
Ref: Wypych, 1995
Problem Quantification
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 9
RubberCurtainsPlenum
Ref: Wypych, 1995
Solution (filter/LEV not possible)
© Wypych, 2013
Ref: US Patent US6135171 (2000)
Passive EnclosureDust Control System
PressureReliefSystem
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 10
Surges and/or Peak Product Flows (Velocity Variations) Minimise Air/Dust “Surges”
Unnecessary Impacts & Dust Generation
PREVENTION: (2) Improved Solids-Air Flow Prediction and Control To Minimise/Avoid:
e.g. ConveyorTransfer
© Wypych, 2013
Validated DEM Simulation: Calibration(Hopper Flow Sliding/Rolling Friction)
Compare: ms, heap and velocity profiles)
VideoVideo
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 11
Bulk Material Calibration for DEM(particle shape, friction, cohesion)
New “Swing Arm” Slump Tester
Video
Video
© Wypych, 2013
Other Special CalibrationTests for DEM Design
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 12
Validation of DEM Scale-Up Investigations CT Design & Testing Thanks to ARC & Rio Tinto
Large-Scale “Dynamic” ValidationConveyor Transfer Facility
© Wypych, 2013
Validated DEM of Hood-Spoon CT
Video
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 13
Validated DEM of Impact Plate CT
Particle Velocity Impact Reaction
Video
© Wypych, 2013
Video
Impact-Plate Conveyor Transfer
© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 14
Case Study: 5000tph Ship Loader
Video Video
Dry Wet
© Wypych, 2013
Case Study: 5000tph Ship Loader(Concept Design Option No. 3)
Video© Wypych, 2013
BMH Week 2013: Env. Mgmt. Conference – Peter Wypych, BMEA, University of Wollongong
4 June 2013 15
Case Study:Iron Ore Wagon Loading & Discharge
Aim: Investigate operational problems with current Iron Ore Wagons and develop options to solve various problems…
1. Unreliable/unpredictable loading (fines; dust)
2. Slow discharge Demurrage costs
3. Incomplete discharge Overloading wagons Exacerbates flow and dust problems
4. Dust emissions: spillage; dust lift-off; unloading; residual ore; collapsing ratholes
Case Study could NOT be presented due toreduced time allowed…to be covered at
Workshop D (6 June 2013) © Wypych, 2013
Thank You !!
Peter [email protected]
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