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 Wypychwypych@uow.edu.au

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 Wypychwypych@uow.edu.au