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Dust Control

Indonesia Customer Seminar

June 13 & 14 2012

Jakarta Indonesia

Dust Control Applications

Typical Coal Handling Facility

Dust Control- Key Programs for Power

DustFoamPlus

Wet surfactant spray Applied @ transfer points

@ 1:2000 dilution
between rail/truck dump
and stockpile

DustFoamPlus

Foam residual dust

suppression;
normally applied
after reclaim

Applied after reclaim @

crushers, transfer points,
tripper deck

Dust-Ban 7977

Prevents windage,
erosion loss on
storage pile

Treatment lasts 30 days

DustBind

Inactive coal pile

crusting agent

3 step application per CPP;

lasts 4 mos. or longer

Haul-E-Z 81201 Residual road dust

control

Also used as belt de-icer,

coal pile freeze protection;
green product, non-glycol

DustFoam, DustFoamPlus

Minimal BTU penalty (< 0.5%

moisture addition)

Residual dust control

> 80% airborne dust reduction is

achievable

Biodegradable

Maximum expansion ratio

Highly effective on PRB

After DustFoam

Before DustFoam

Typical Foam System Layout

IMPORTANT
TOTAL HOSE
LENGTHS FROM
EXPANSION
CHAMBER TO
SPRAY NOZZLES
MUST BE 30 FT
OR LESS.

Expansion
Chamber

Plant Air
Plant Air

Control
Module

Solution (Water /Chemical)

ALL HOSES MUST

BE IDENTICAL IN
DIAMETER &
LENGTH.

Electrical
Auto/Switch

Material and/or Motion Sensor

DustFoamPlus
Chemical

Plant Water

Standard 800 TPH Foam System

Model DF20S Standard Control Module

Mounted in a 42x 36NEMA 4 dust tight Cabinet.

20 GPM water driven dosing pump.
Air, water and solution lines, check valves.
Air/water Pressure regulators, gauges and Flow meters.
Air/solution Flow control ball valves with air actuators.
2 100 mesh water strainer and 200 mesh filter.
Purge system for freeze protection.

Electric control options

Model DFCP- PL Logic control panel for auto on/off operation.
120 VAC PLC controls mounted in a 16x 14 NEMA 4X Cabinet.
(or)

Model DFCP-S Standard Relay panel for auto on/off operation.

120 VAC standard relay controls mounted in a 16x 14 NEMA 4X
Cabinet.

Expansion Chambers
24x 6, 30x 6 or 40x 6 (depending upon required foam output)
expansion chamber with top and bottom fittings, control valves, gauges
and up to 6 foam outlets.

Excellent dry stable micro bubble structured Foam

Excellent dry stable micro bubble structured foam sprays

Inefficient poor large bubble structured Foam

DustFoam Spray to Head Box

Radial Stackout With and Without DustFoam

Wet Suppression @ Rotary Car Dump

Dust Monitoring Equipment

13:56:12

13:49:12

13:42:12

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13:00:12

12:53:12

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16:07:12

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14:49:12

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12:00:12

11:47:12

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11:08:12

10:55:12

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10:03:12

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08:58:12

08:45:12

08:32:12

mg/m3
5

12:39:12

12:32:12

12:25:12

12:18:12

12:11:12

12:04:12

2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0

11:57:12

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11:01:12

10:54:12

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10:05:12

09:58:12

09:51:12

mg/m3

Monitoring Results With & Without DustFoam

(Vibratory feeders under reclaim pile)

2A Feeders W/O Dustfoam

Avg. 1.37 mg/m3

Max. 12.9 mg/m3

2A Feeders With Dustfoam

Average 0.188 mg/m3

Maximum 2.7 mg/m3

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mg/m3

Crusher Building Dust Test

DustFoam Test Data
40

35

No Treatment

Dust Level

DustFoam Treatment

30

25

20

15

10

Running 5 Minute Average

Live Storage With & Without DustFoam

Filling Water Truck for DustBind Application

Spraying Pile With DustBind Solution

Spraying DustBind With Water Cannon

DustBind Surface

Dust Control

Rule of Thumb: 1 spray or foam application (at transfer

point) for each 500 tons/hr coal flow; e.g., if 600 tons/hr
coal flow, 2 application points are required

Off-the shelf foam equipment supplied by Viking Equipt.,

Inc.

CPPs for the various dust control products contain

detailed application instructions

A 500 MW unit burns 230 tons/hr bituminous coal, hr,

i.e., 0.460 tons/MW

Freeze Conditioning Agent (FCA)

Eliminice 8882 Belt Deicer (can be used as haul road

dust control agent also)

Nalcos patented glycerin-based FCA; a very unique

green product

Other commodity-type FCA have big drawbacks:

Glycol FCA products are very toxic
Calcium chloride is corrosive to coal handling equipment and
boiler internals

Nalco 8880 used for coal load-out, side release agent in

coal rail cars, etc.

FCA spray equipment systems available from Viking

Equip. or Boggs Municipal Services Co.

Problem Locations for Wet Coal

Wet Coal Flow Additive

Injection
nozzle assy

Coal feeder

Case study: Wet Coal Flow Additive

165 pulverized coal-fired unit (PRB coal)

Wet coal plugs between the coal feeder(s) and the

pulverizers

DustCon injected as neat product into downcomer chute

@ 0.25-0.50 pints/ton

Use standard feed skid (part no. IM1A02A0.88) with

hollow cone nozzle assy

Best results when fed intermittently; 15 min. to one

feeder, then 15 min. to the next, etc. (4 feeders total)

Coat inside surface of downcomer chute

Treatment prevents loss of 1 feeder, 25% of total coal

feed to boiler

DISCUSSION