Road Dust Control Clinic

Dust Control Offering

Tools in the Box
Product

Type

Road

Material
Transfer

Surface
Binding

CT-9030

Surfactant

Yes

Yes

No

CT-936

Surfactant

Yes

Yes

No

Ct-9040

Foam Agent

No

Yes

No

CT-9054

Ligno

Yes

Yes

Yes

CT-9054S

Ligno/Surfact

Yes

Yes

Yes

CT-9064

Organic Polymer

Yes

Yes

Yes

CT-904X

Residual Foam

No

Yes

No

CT-907X

Humectant

Yes

No

No

CT-908X

Tar Emulsion

Yes

No

No

Dust Control Terms

Dust Control Terms

DUST
Dust is defined by the Mine Safety and Health Administration as finely divided solids
that may become airborne from the original state without any chemical or physical
change other than fracture.
These fracturing processes include crushing, grinding, impact, abrasion, transfer
operations, loading, dumping, driving over materials, wind erosion, etc. Anytime
materials are handled dust is generated in varying amounts.
While dust generation is unavoidable in many material processing operations, it must be
controlled to reduce health hazards, reduce equipment damage, improve visibility, for
community relations aspects and to meet government regulations.

Dust Control Terms

DUST HAZARDS
The problem with these finely divided solids is they are not all the same. Some are
heavy enough to settle out of the air, while others are fine enough to remain airborne
indefinitely. Some are nuisance dusts which decrease visibility and cause unpleasant
deposits in the eyes, nose, throat and ears, but are relatively benign to the human body.
Others are fibrogenic and cause a host of problems like silicosis, black lung disease,
cancer, etc.
The dust particles to be concerned with are all dust particles that fall into the
Occupational Safety and Health Administration (OSHA) category of PM10 or
Particulate Matter 10 meaning the dust particles are ten microns or smaller. One
micron equals 1/25,400 of an inch. For comparison, an average human hair is from 50 to
75 microns across, hence, these particles are one-fifth the diameter of a human hair and
smaller.
These are the dust particles that get stuck in the human lung and cause damage. They are
known as respirable dust and can include both nuisance and fibrogenic dusts.
Respirable dust particles are small enough to remain airborne for long periods of time if
they are not subjected to some outside influence such as dust suppression or collection.
Fibrogenic dusts cause diseases such as black lung, silicosis, asbestosis, etc. These types
of dust are very dangerous.

Dust Control Terms

DUST HAZARDS (cont.)
Visibility/opacity hazards created by dust.
Some areas of processing plants can become so loaded with airborne dust that opacity becomes
100% and visibility is reduced to zero.
Accidents can and do happen in these areas, whether they are in an enclosed structure or out in the
open.
Machinery also takes a beating in heavily dust-laden atmospheres.
1. Motors overheat because they cannot dissipate heat through the dust layer covering them
2. Bearings ingest dust and grind themselves apart
3. Equipment in areas with high air velocities will literally be sandblasted by dust entrained air.
Each of these items adds to maintenance and repair costs.
Negative Community relations
.
.

Surrounding neighbors can attract great attention to their cause of reducing airborne dust
Even to the point of getting the local media involved, which is a sure sign, the government
inspectors and regulators will follow.

Dust Control Terms

DUST CONTROL
Dust control technology involves designing a system specifically for a particular dust
problem. A dust control system will consist of one or more of the following:

Containment this is the first step in controlling dust because of the need to control
the material stream and the associated air movements before dust control can be
successful.
Containment involves adding or rebuilding chutes, chutewalls,
wearliners, sealing systems, entrance and exit treatments, etc.
Another form of containment used to reduce wind velocities in open areas to prevent
re-entrainment of dust and to aid in the effectiveness of dust suppression
are Wind fences.

Dust Control Terms

SUPPRESSION
Plain water was the first type of dust suppression method. This method of wet suppression was
improved through better spray nozzle technology, which enhanced the dust capture. While usually the
least costly at initial installation, it is also the least effective in controlling many types of dust.
Some material cannot tolerate large amounts of water. Fly ash and cement will set up if water is added.
Coal dust will simply float on the surface of water without actually being wetted. Fuels such as coal,
wood, trash and hog fuel incur large BTU penalties when large amounts of water are added. Plain
water can also be considered to be point specific. When the water evaporates, the dust control ends.

Water/surfactant used mostly in truck, railcar dumps and road-spraying trucks, water/surfactant
consists of water and a surfactant chemical being sprayed onto a material or into the air to capture
airborne dust or prevent dust from becoming airborne. Next to the fire hose (plain water) technology
this adds the most water to a given material. (A surfactant is any chemical that alters waters properties
to improve its wetting abilities.) Water/surfactant mixes can be considered to be residual in that they
will provide some dust control at points farther along the material stream flow.

Dust Control Terms

Foam is a further advancement in wet suppression technology and is made by

combining water, surfactant foaming agents and air in specially designed foam generating
equipment to produce stable micro bubble structured foam. These bubbles capture dust
particles and prevent dust from becoming airborne. If dust can be kept in the material
stream, it does not have to be captured or treated in the air. This is a considerably more
effective way to deal with dust.
Foam has the lowest moisture addition of any wet suppression technology, with the
exception of fogging. By combining the proper proportions of air, water and chemicals,
the surface areas of a given amount of water can be expanded by a factor of sixty to
eighty times.
By expanding the surface area sixty to eighty times, the amount of water needed to treat a
specific volume of material can be reduced by that same factor. The foam bubble
surfactant concentration is much higher, providing increased wetting ability. Foam has
the ability to adhere to falling material, allowing increased contact time for the bubbles to
penetrate and impact the dust particles.

Dust Control Terms

Foam

- A well-designed foam system reduces the moisture addition to 0.4 - 0.8

gallons per ton of treated material while improving the probability of dust capture.
Foam systems typically reduce water by 85% to 95% over water spray suppression
methods.
(cont.)

Water reduction can be of great value when dealing with materials that cannot tolerate
large volumes of water. Chute pluggage, freezing problems and BTU penalties are all
reduced.
In addition, foam also offers a residual benefit.

Dust Control Terms

Fog is formed by pressurizing plain water and forcing it through nozzles that atomize
the droplets. The smaller the droplets, the better chance they have of contacting and
capturing dust particles. Fog adds the least amount of water but is the most sensitive to air
movements since the droplets are small enough to be blown out of the treatment area. Fog
is also point specific in there is no carry over to the next dust generation location.
Which system to use and where to apply it are based upon factors such as the materials
tolerance to moisture addition, water sources close to the application points, physical size
of the area to be treated, temperature of the material generating the dust, climatic
conditions, prevailing winds, treated tonnages, material reduction and handling sequences,
etc. Many factors must be taken into account when designing a dust control system for a
specific operation. Changing materials, material specs, belt loadings, belt speeds, or other
operating parameters will change the dust control requirements. These factors must also be
taken into account.

Dust Control Terms

DUST COLLECTION
Collection is now commonly used in conjunction with suppression or in some areas as a
standalone technology.
Dust collection systems capture airborne dust from the source either by filtering the air in
the area of the dust generating mechanism (insertable collectors) or by transporting dustladen air to a central location of filtering/cleaning (baghouse or central collectors).
Insertable collectors allow air to pass through fabric filter elements to remove dust from
the air. The filtered dust is allowed to agglomerate or cake to the filter elements until the
particle clumps are heavy enough to be dislodged and dropped directly back into the
material stream without the use of transport ducting, ancillary equipment or the problems
of disposing the collected dust.

Dust Control Terms

DUST COLLECTION (cont.)

Central collectors transport dust-laden air to a central cleaning point through the use of
ducting and collection hoods. The cleaning process is the same as the insertable
collectors; however, the collected dust must either be disposed of or returned to the
process material stream at some point.
Collection is point specific. Unless specifically designed into the system, there is no
residual treatment of the dust being collected. Dust is either disposed of or returned to
the process material stream to more likely than not become airborne at some other point
in the system.
Collection at one location will not have any effect on the next location where dust is
being generated.

Why Dust Control?

Government Regulations
Health Concerns
Safety Concerns
Environmental Compliance
Reduced Operating Costs
The Cost of not doing it

Respiratory Dust Deposition Areas

Inhalable < 0.01 to < 100 mm

Thoracic < 0.01 to < 10 mm
Respirable < 0.01 to < 3 - 5 mm

Particles > 100 mm settle quickly

(un-inhaled)

Who needs clean air ?

Plant Managers
Production Managers
Safety Directors
Maintenance Managers
Employees
Neighbors

Negative impacts of not doing it?

Increased Health Costs

Increased Safety Costs
Increased Production
Costs
Lost Material Costs

What is Dust?
Finely divided solids that may become airborne from their original state
without any chemical or physical change other than fracture
Individual dust particles are measured
in microns.
Ten thousand microns equal one
centimeter, or 0.3937 inch.
EPA classifies particulate matter in two
sizes.
Particles smaller than 2.5 microns are
referred to as PM2.5.
Larger particles up to 10 microns in
diameter are designated PM10.
The PM10 classification includes most
types of fugitive dust

Dust - Influencing Factors

Particle Size
Surface Moisture
Hydrophobic (difficult to wet)
Hydrophilic (easy to wet)

Air Movement (velocity)

Displaced Air
Induced Air
Generated Air
Climate
Precipitation, Wind, Temperature

The Mechanics of Dust

In order to have fugitive dust, two (2)

fundamental aspects must be met.
1. Fine particulate matter must exist
2. There must be air velocity

Sources of Dust

Material Impact
Crushing
Screening
Conveying
Stockpiling
Reclaiming
Loading
Transporting
Vehicle traffic
Wind

Dust Control Methods

Containment - Physical Barriers

Suppression - Water, Chemical

Collection - Extraction Systems

Suppression

Suppression is the use of water alone or in

conjunction with specialized non-hazardous
chemicals
to wet and agglomerate or bind small particles
together preventing them from becoming airborne
or
to wet existing airborne particles so that they
agglomerate and increase in density and are no longer
able to remain airborne

Definition of Treatment
Continuous
Treatment

Road Residual Treatments

24 hours/day

Short Term
(Hours)

Medium Term
(Days)

Long Term
(Weeks)

Watering

Surfactants

Emulsions
Tar
Latex
Petro

Chlorides

DOSS

Lignins

Magnesium
Calcium
Sodium

Humectants
Organic Polymers

Plain water..Friend or Foe?

Nalco
additive: Water
/: WaterRatio
Ratio
Surfactant
Water Surface
Tension

Typical
water

Distilled
water

1 : 2000

1 : 4000

1 : 6000

1 : 8000

1 : 10,000

Dynes/cm2

72.5

70.0

33.4

34.7

36.1

37.4

39.3

Newton/m2

0.072

0.07

0.030

0.035

0.036

0.037

0.039

Lower Dynes/cm2 indicates better wetting potential

Not All Surfactants are Created Equal

Road Dust Control

Typical Cost Factors
Trucks

Drivers
Fuel
Maintenance/parts
Corrosion

Water
Water rights

Adequate supply
Pumping costs

Road Treatment Application Methods

Traditional road spraying

Used with an
enhancement program

Road Treatment Application Methods

Pressurized Spraying
Residual dust control
treatment

Agenda

Inefficient gravity spraying

Road Dust Control

Deluge Gravity Spraying

Over saturated road surface

Over Saturated road = Higher Costs

1. Wasted Resources
2. Road Degradation
3. Destabilize Road Base
4. Rutting
5. Pot Holing

Preferred pressure spraying

Road Dust Control

Pressurized
Spray bar

Surface Preparation

Poor Road Surface

Ideal Road Surface

Surface Preparation

Ideal Road Surface

Surface Preparation

Lay Down Yard

Before

Plant Service Road

After

Plant Service Road

Application Examples
Extended Residual Programs
Case A.
Initial application: 70% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 2 weeks after initial application, light spray with
water only to keep the product activated.
5 weeks after initial application: Re-apply at a 30% solution.
8-9 weeks after initial application: Re-apply at the initial application rate.
Case B.
Initial application: 60% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 8 - 10 days after initial application, light spray with
water only to keep the product activated.
5-6 weeks after initial application: Re-apply at a 60% solution.
Case C.
Initial application: 50% solution applied at a rate of 1 Qrt per square yard.
Maintenance applications: Every 10 days after the initial application, light spray with
water only to keep the product activated.
Every 4-5 weeks after initial application: Re-apply at a 50% solution.

Advantages of Long Term Residual Program

Improved road safety
Reduced water consumption
Reduced road maintenance - Grading
Reduction in labor costs
Lower equipment costs (water trucks)
Reduction in truck maintenance costs
Reduction in fuel costs
Providing a cleaner and safer work environment for employees
Eliminating friction and complaints from neighbors

How do you measure Dust Control

Performance?

Chemistry

Tangible

Intangible & Immeasurable

FREQUENCY

SAFETY
ENVIRONMENT

EZ of
CLEANUP

OTHER

Multi/day

X-tra Traffic
Wet/slippery

Yes

Muddy,
Morale

Oils/Tar Emul

7-14 days

Slippery
Run-off (PAHs)

No,
Morale

Oil base,
None
Renewable

Ca/MgCl2

30-45 days *

Toxic

Yes

Highly
Corrosive!

Humectant &
Organic Poly

30-60 days *

Bio-degrades

Yes

Renewable
Resource

Water

EPA Requirements

The current EPA standard for PM10 is an annual

average of no more than 50 micrograms per
cubic meter.
For comparison, an enclosed area 100 feet
long by 100 feet wide and 20 feet tall would
be allowed a total of 0.2832 gram, or 0.0091
ounce of suspended dust particles in the air
to meet the annual average.

EPA Requirements

Additionally, there is a standard of 150 micrograms

per cubic meter in any 24-hour period.
This is the maximum acceptable acute level;
communities/companies are allowed to exceed
this level only once a year over a three-year
period to stay in compliance with clean air
standards.

Dust Control Performance Monitoring Methods

Hand held instruments Grab

Samples
Moment in time
Milligrams/m3
Download data to CPU for
analysis.
Volumetric Grab Samples
Samples taken over extended
time frame
Taken to lab for analysis

Performance Monitoring Systems

ADR Dust
Monitoring
System

Site Wide Integrated Dust Monitoring System

Site Wide Integrated Dust Monitoring System

Dust Control Performance Data Gathered

Total Dust Reading mg/m3

Particle Size Distribution microns
Wind Direction & Velocity
Samples taken 1 sec to every 4 minutes
Record of up to 10 days of data Down loadable
Wireless connection for data management
Web reporting capability restrictable access
Volumetric sampling capability
Integrated Dust Management Approach
Road, Material Handling, & etc.

Dust Control Performance Monitoring

Best Practices
1. Identify all potential fugitive dust emission sources
Example Drag Out, Drift & Transport Spillage
2. Assign Dust Control methods

What will be done in which areas (High Traffic, Low traffic)

Map out areas by treatment methods
Best Chemistry for Road Base Material

3. Determine frequency of treatment methods

Best Technology for application

4. Establish meaningful monitoring sites

Frequency of Sampling is critical to be meaningful

Weather Conditions correlated to dust sampling

5. Data Log all the above activities

Allows for optimization of Dust Control Plan

Dust Control Vocabulary

Dust Control Vocabulary

Respirable
Dust

Dust particles that measure 10 microns or less in diameter. These dust particles can be
inhaled into the respiratory system and become lodged in the lungs. Depending on the type
of dust, prolonged exposure to respirable dust can cause fatal respiratory illnesses such as
Black Lung and Silicosis.

Total Dust

All dust particles regardless of size. Regulation of total dust is typically required when the
dust is considered to be a nuisance and less of a health hazard, i.e., limestone dust in a rock
quarry.

Fugitive Dust

The particulate that is captured in the atmosphere that does not allow itself to fall to the
earth of its own weight.

Static
Pressure

A force that expands or compresses the air in a chuted area. This pressure will cause dust to
be forced out of the transfer chute, through leaking skirtboard seals or tail box assemblies.
This type of pressure can be positive or negative.

Velocity
Pressure

A force causing a volume of air to accelerate from rest to a particular velocity. Air
velocities create airborne dust and are always positive.

Capture
Velocity

Air velocity required to overcome opposing air currents for the purpose of capturing
airborne dust.

Dust Control Vocabulary

Carrying
Velocities

Air velocity required to suspend a dust particle. Bulk density and particle size determine
this required velocity.

Terminal
Velocity

Maximum attainable speed while falling through the atmosphere subject to the gravitational
pull of the earth and not taking into consideration any velocity associated to the material
transfer.

Silicosis

This is an irreversible lung disease caused by inhaling silica dust particles. As dust particles
become lodged in the lungs, scarring of the lung tissue occurs, resulting in shortness of
breath.

Black Lung

This is an irreversible lung disease caused by inhaling coal dust particles. As dust particles
become lodged in the lungs, scarring of the lung tissue occurs, resulting in shortness of
breath.

Induced Air

Collected by the moving products as it leaves the head pulley of the conveyor.

Pitot Tube

A device used in conjunction with a manometer to measure static pressure and total pressure
in a collection duct or transfer chute.

Dust Control Vocabulary

Threshold
Limit Value
(TLV)

Dust concentration standard required by the Mine Safety and Health Administration,
measured in mg of dust per M3 of air. Each bulk material has a specific TLV.

Permissible
Exposure
Limit (PEL)

Dust concentration standard required by the Occupational Safety and Health Administration,
measured in mg of dust per M3 of air. Each bulk material has a specific PEL.

Time-Weighted Dust standards as set of OSHA and MSHA are measured over an 8-hour time-weighted
average.
Average
PM10

Particulate matter 10 micrometers in diameter or smaller includes dust particles of 10

microns in diameter or less. These particles are considered respirable and the most harmful
of all sizes of dust particles. A dust particle of this size is between 1/10 th and 1/100th the
diameter of the average-sized human hair, and is invisible to the naked eye.

Point Source
Solution

This is a dust control solution that controls the dust only at the point of application. Examples
of this include dust collection and fog dust suppression technology. These technologies may
be required at each dust emission source where they treat the dust-laden air.

Dust Control Vocabulary

Residual
Effect
Solution

This dust control solution can be applied at one dust source and provide residual dust control
at several possible dust sources after initial application. Examples of this include foam dust
suppression and water/surfactant dust suppression. These technologies actually treat the
dust-laden material before the dust becomes airborne.

Agglomeration Dust particles collide with water droplets and other dust particles or material, sticking

together and increasing in mass. The increased mass forces the agglomerates to fall from
the air and return to the main material flow, or stay with the main material flow, depending
on when the agglomeration occurs.

Suppression

The ability to suppress or not allow something to happen by the use of a method or piece of
equipment.

Foam Dust
Suppression

This is a residual effect solution that combines a solution of water and surfactant along with
compressed air to expand the surface area of the solution to capture dust. This foam is then
mixed with the material for the purpose of agglomerating the fine dust particles with the
main material flow. This technology can add between 0.1% and 0.4% moisture addition by
weight.

Dust Control Vocabulary

Water/Surfact
Dust
Suppression

This is a residual effect solution which combines a solution of water and surfactant to make
the water wetter and allow agglomeration to occur between the water droplets and the dust
particles. This solution is then mixed with the material for the purpose of agglomerating the
fine dust particles with the main material flow. This technology can add between 0.4% and
2.5% moisture addition by weight.

Surfactant

A chemical that is added with water to alter its surface tension. This allows the water to
adhere to bulk material to promote agglomeration. Many materials are not water friendly
and will not agglomerate with water unless surfactant is used. For example: if you wash
your hands with soap, they will be much cleaner than if you only washed them with water.
The soap acts as the surfactant.

Tackafier

This is an additive added to water that adheres to bulk material to give it long-term residual
dust control, even after the water evaporates. This can be used in rail cars to minimize
windblown dust loss, or to live storage piles.

Crusting
Agent

This is an additive added to water and is sprayed onto dead storage piles to reduce oxidation
and break down bulk materials. This seals the top layer of an undisturbed dead storage pile,
minimizing windblown dust emissions.

Dust Control Vocabulary

Fog Dust
Suppression

This is a point source solution that applies small water droplets into the airflow. These
water droplets are similar in size to the dust particles, which promote agglomeration
between the dust particles and water droplets. This technology can add between 0.1% and
0.5% moisture addition by weight.

This is a point source solution that filters dust-laden air at the source. Agglomeration of the
Insertable
Dust Collector dust occurs on the collection bags, forming a filter cake, and returning the agglomerated dust
particles to the main material stream.

Central Bag
House Dust
Collector

This is a point source solution that filters dust-laden air through a centralized location by
transporting the air through dust collection ducts. The collected dust is then processed
through agglomeration by adding water or binding agents. This agglomerated material is
then either reintroduced into the material handling process or is disposed of, depending on
the specific material and process. This technology provides 90% plus efficiency of
collection.

Central
Mechanical
Dust Collector

Dust is collected and transported to a central location. When the dust reaches the collector
cyclone, the weight of the dust allows the particles to settle out into a hopper. The material
is then either reintroduced into the material handling process or is disposed of, depending on
the specific material process. This technology provides 60% plus efficiency of collection.

Dust Control Vocabulary

Personal Dust OSHA and MSHA require that employers perform periodic personal dust sampling. This is
done by using a filter cassette assembly, cyclone, and personal sampling pump. This test is
Sampling
completed over an 8-hour time-weighted average.

BTU Penalty

This is a factor to be considered whenever a thermal process is being used, i.e., coal is being
burned for fuel, clay is being dried for the manufacture of cement, etc. A BTU is a British
Thermal Unit. All fuels have a specific BTU rating. When moisture is evaporated from the
material in the process of burning the fuel or drying the material, it requires energy to
evaporate that moisture. This lost energy is termed as the BTU Penalty and can be
calculated in terms of dollars.

Compression

Material laying on a conveyor belt with its cross sectional area being as dense as it will ever
be with the given material size as opposed to free-fall.

Bulk Density

The weight of material in pounds/ft3.

Dust Control Vocabulary

Inherent
Moisture

The amount of moisture that is atomically bound inside the individual material particles.

Surface
Moisture

The amount of moisture that is externally added to material flow and can run off of the
material.

Flashing of
Chemical

The ability of chemical to turn to steam or evaporate with temperature leaving the
suppression of little or no effect (generally 190-220F).