DUST SUPPRESSION DIVISION SYNTRONINDUSTRIES

Date: 01/08/2006 AHMEDABAD – 382 445, INDIA

COST EFFECTIVE

DUST SUPPRESSION SYSTEM

WITH THE HELP OF

TECHNO – ECONOMICAL PRODUCT

DUSTRON XT COMPOUND
IN OPEN CAST MINERAL MINES / INDUSTRIAL MINERAL
HANDLING PLANTS

Product Code2001

DEVELOPED & MANUFACTURED BY:

SYNTRON INDUSTRIES

411/5,Phase-II, G.I.D.C Estate, Vatva,

Ahmedabad-382 445.GUJARAT.INDIA.

Marketed by:

NRD INDUTRIES

86 Commonwealth Ave, Piscataway, NJ08854. USA. Ph : 732-819-7932

E-mail : ,

PERFORMANCE EVALUATION & FIELD APPLICATION SYSTEM BY:

CENTRAL MINING RESEARCH INSTITUTE

(Council of Scientific & Industrial Research)

Barwa Road, Dhanbad -826 001 (Jharkhand)

Note: Date of Revision / Modification of Technical Paper:01/08/2006

All other Technical literature of earlier date / without date is cancelling from the above date.

GLIMPSE

OF

DUSTRON XT COMPOUND

  • FULLFILS

DGMS TECH. CIRCULAR No.8 OF 1997.

ACT 14 OF 1981 & THE AIR PREVENTION & CONTROL OF POLLUTION AMENDMENT ACT 47 OF 1987 & DGMS TECH. CIRCULAR No.05 OF 1987.

CIRCULAR – B-33014/7/90/PCI-II/9316 OF 2000 OF MINISTRY OF ENVIRONMENT & FOREST / CENTRAL PLLUTION CONTROL BOARD.

RCRA (RESOURCE CONSERVATION AND RECOVERY ACT) OF USA.

  • DUST FREE ENVIRONMENT
  • BIODEGRADABLE
  • ENVIRONMENT FRIENDLY
  • NONTOXIC
  • AIR BORNE DUST UNDER PERMISSIABLE LIMIT
  • NO EFFECT ON

HUMAN HEALTH

AQUATIC LIFE

PLANT & GRASS

EARTH WORM

  • NO DISEASES OCCUR

DUE TO DUST

DUE TO FUNGI (OVER WATERING)

  • DOES NOT BASE ON

CHLORIDE

PHENOL

WASTE OIL

  • MINIMUM SAVING

WATER – 60% In 1:2500 & 40% in 1:5000.

ELECTRICITY / DIESEL FOR PUMPING OF WATER

  • NO

MINERAL SLURRY / MUD FORMATION

STAG DUST FOUND IN THE WINTER SEASON

FIRE HAZARD OCCUR

ACCIDENTS OCCUR

  • INCREASES IN COMPARISION TO NORMAL WATER SPRAYING

PRODUCTION & PRODUCTIVITY

LIFE OF SPARE PARTS OF HEMM & LMV

LIFE OF LUBRICANTS

LIFE OF TYRES

LIFE OF SPARES PARTS OF CRUSHER & CONVEYOR ROLLER

(About 20% for Mild steel, 62% for Bronze, 17% for Copper, 74% for Aluminium)

  • DECREASES IN COMPARISION TO NORMAL WATER

THE MAINTENANCE COST OF SPARES PARTS OF CRUSHER & CONVEYOR ROLLER

DUSTRON XT COMPOUND FOR CRUSHING & HANDLING PLANT IN MINERAL (IRON, CHROMITE, MANGANESE, BAUXITEORE, etc) BASED INDUSTRIES

In Mineral Mining Industry Formation of Dust is an Everyday Occurrence both in underground & Open Cast Mines. As per Mines Regulation 1957, elaborate precautions have been mentioned under regulation 123 to eliminate DUST. HAZARD in Mines & under DGMS circular No. 31 of 1966, circular No. 62 of 1966, circular No. 40 of 1967 & circular No.16 of 1975 had advised the Mining industry to use wetting agents for suppression of DUST.

The DUSTRON XT COMPOUND fulfils the requirement as stated in DGMS Tech. Circular No. 5of 1987 & Circular (Tech.) 8 of 1997.

As per the Air (Prevention and Control of Pollution) Act 14 of 1981& the Air Prevention and Control of Pollution) Amendment Act 47 of 1987, states that to take appropriate steps for the preservation of Natural Resources of the Mining & Industrial Area / the Earth which, among other things, include the preservation of quality of Air and control of Air Pollution

The DUSTRON XT COMPOUND fulfils theAct 14 of 1981 & the Air Prevention & Control of Pollution Amendment Act 47 of 1987.

According to Committee constituted by Ministry of Environment and Forest (MOEF) / Central Pollution Control Board, Circular No.B-33014/7,90/PCI-II/9316, May 23rd, 2000 that the Minerals Mines can only use those products which are Bio – degradable and does not based on Chloride, Phenol and Waste Oil.

The DUSTRON XT COMPOUND also fulfils the all parameters of the above circular of Ministry of Environment and Forest (MOEF) / Central Pollution Control Board.

THE HAZARD OF DUST

1Serious Hazard to the health of the workers leading to dreaded DISEASES like SILICOSIS, PNEUMOCONIOSIS, BRONCHIAL ASTHMA, FIBROSIS OF LUNGS, TUBERCULOSIS (TB) etc.

  1. Particles are broken in two types, ROUNDED & ANGULAR in which angular particles of Dust are very harmful for the health. Less than (-5) Micron size Dust are not CONTROL by the NOSEHAIR and Angular Dust that are less than (-5) Micron are Penetrated into Lungs that are the causes of Lungs Diseases.
  1. In the Crusher area, the Mineral Dust are blowing with the speed of air and the Air Borne Dust are spread over the Crops, and also in the populated area which are harmful for the People, vegetation, Forests, Animals & Cattle and Water Resources also, not only in Mining area, also in total surrounding area of mines.
  1. Due to fast moving of Mineral Dust from the Crusher Area &/or Mineral Handling Plants with Air, the YIELD DEFICIENCY of Mineral is regular feature which is a NATIONAL LOSS.
  1. Due to large amount of DUST GENERATION, the PRODUCTION always HAMPERS.
  1. The DUST CORROSIVE effect SHORTENS the LIFE of costly Heavy Moving Machinery’s (H.E.M.M.) & increases the Maintenance cost which is a NATIONAL LOSS.
  1. The DUST also shortens the life of LUBRICANTS.
  1. Effects Operating Efficiency of H.E.M.M. and also impedes VISIBILITY thereby REDUCING PRODUCTION Capacity & creates a Potential SAFETY HAZARD both in UNDERGROUND & in OPENCAST MINES.

LIMITATION OF TRADITIONAL WATER SPRAYING METHOD TO CONTROL DUST

1Water - Spray will attract only heavier particles leaving fine particles to continue to blow away.

2Water evaporates quickly & therefore hot dry climates prevent it from having very little ability to suppress dust.

3The finer particles formed as DUST FILM particles will blow away & very fast dry the water and finer particles will blow away with water.

4The Air borne dust are not absorbed / attached with plain / simple / NORMAL WATER.

5On using, excess amount of water to control full dust, huge water is also a problem to pump out from the crusher area with Mineral slurry.

M/s. SYNTRON INDUSTRIES had developed DUSTRON XT compound, to control this type of pollution of dust before it becomes AIRBORNE in Mines, Mineral Handling plants, Thermal Power Stations, Ports, dams, Cement and Fertilizer industries, etc; where large quantity of bulk solid materials are handling in a very high speed. The very fine dust of particles of size less than (-10) microns are quickly airborne and remain suspended in air at transfer point area.

On the basis of report of CMRI, Dhanbad, indicates the following percentage of emission of Dust:

S. No. / Part of Handling Plant / Air Borne Dust in %
01. / Crushing / 1-15%
02. / Screening / 5-10%
03. / Stockpiling / 10-30%
04. / Reclaiming / 0-10%
05. / Belt Conveyor System / 30-60%

Common practice to use plain water spray is not an efficient remedy. It does not:

  1. Wet dust particles are partially water repellent.
  2. Agglomerate the finer particles of the dust.

To increase the efficiency of the spraying system, it is essential to improve the physical phenomena between the water and the dust particles and to improve the surface tension of water. DUSTRON XT compound is recommending for various applications to work effectively as under:

DUSTRON XT produces interfacial tension between the particles of dust to produce agglomeration of the macron and micron size particles.

DUSTRON XT lowers the water surface tension to create smaller droplets and effect greater spray dispersion for more efficient area coverage.

DUSTRON XT prevents the formation of the dust film restricted to the water surface, allows the dust to penetrate the surface of water droplets and permits less moisture to do more efficient job.

Dust pollution is mainly produced in the Coal/Ore handling plants of the Coal/Ore mines, thermal power stations etc., due to different operations such as transportation at transfer points like dumper / tipper to hopper, conveyor to conveyor, conveyor to wagon / tipper, etc., which cause great interference’s in waking, effects the human health.

The surface tension of water is 72 Dyne/Sq. cm, which is, reducing to approx. 26 Dyne/Sq. cm with addition of DUSTRON XT compound.

Pre – treatment with the DUSTRON XT spray at this stage is most important for wetting the surface to cause agglomeration of smaller particles PRIOR to the dust creating process.

DUSTORN XT spray creates smaller droplets and covers more area to increases the moisture spread in the material pre-treatment. The isolation of the dust emission area by a thin curtain of the moisture keeps the dust with in the treatment zone.

Airborne dust is suppressing by entrapment of the particles in fine droplets of DUSTRON XT solution. Smaller particles agglomerated and made heavy, lowering their precipitation on the mass of the source material.

Prior to processing actions such as crushing, screening etc. the material is pre-treated and then additional treatments are giving to achieve the dust suppress on whenever it is created by materials processing operations. Regardless of the number of treatment points, the moisture added is seldom more than 1 %.

TO IMPROVE DUST CONTROL, BETTER DUST SUPPRESSION SYSTEM IS REQUIRED WITH FULLCORN, SPRAY, ETC. TYPE NOZZLE & PRESSURE PUMP ON LINE CHEMICAL DOZZING PUMP & STATIC MIXTURE IS FITTED FOR ECONOMICAL SYSTEM

DUSTRON XT has a non- ionic, non – volatile nature and has prolonged store stability in seal conditions. On prolonged storage, discoloration or change in the colour may be observed but it does not reduce the efficiency of the product. The product does not produce any corrosion.

Now R&D section, M/s SYNTRON INDUSTRIES has developed DUSTRON PC /XT compound for different types of minerals & coalmines & handling plants. Such as, DUSTRON PC COMPOUND only for open cast Mineral mines haul roads & dump yard section & DUSTRON-XT-COMPOUND is for open / underground Mineral mines, in Mineral crushing plants, Mineral handling point (hopper to crusher, crusher to conveyor, conveyor to conveyor & conveyor to dumper /Trucks/Loading point).

MATERIALSPECIFICATION & CHARACTERISTICS

DUSTRON – XT COMPOUND is a derivative compound of CARBON; OXYGEN & HYDROGEN based aqueous non – ionized bounding material suitable for open cast mines Mineral / Industrial Mineral Handling Plants for dust consolidation.

S.No. / Test Properties / Result
01. / Physical Form / Blue Colour Liquid
02. / Ionic Character / Non-ionic
03. / Molecular Weight / 568 approx (average)
04. / Major Component Ratio / Carbon : 60.55 Parts
Oxygen : 28.70 Parts
Hydrogen : 10.45 Parts
Nitrogen : 0.30 Parts
05. / Active Matter/ Solid Content / 88+ 2%
06. / Solubility / Easily Soluble with water
07. / Stability / Stable in hard & brackish water
08. / pH / 7 to 7.5 (Neutral)
09. / Corrosion Test in / Non Corrosive
Comparison with tap water / Improve the life of metal (tanker & accessories
Of spraying system
Result shows the / Metal Result
Tested sample / Mild Steel – 20%
Bronze – 62%
Copper – 17%
Aluminium - 74%
10. / Specific Gravity / 1.05+ 0.05
11. / Phenol / Nil / Not present
12. / Chloride / Nil / not present
13. / Waste Oil / Nil / Not present
14. / Bio – degradable / Bio – degraded within limited period
S.No. / Test Properties / Result
15. / Hazardous & Toxic Metal / ANYALYTE / Regulatory Levels mg/L
MOEF/CECB/
CIL Limit / Results with Detection Limit ppm (mg/L)
Result shows the / Metal / RCRA Limit / Results
Tested sample / Arsenic (As) / 5 / Nil
Barium( Ba) / 100 / Nil
Cadmium (Cd) / 1 / Nil
Chromium(Cr) / 5 / Not detected
Lead (Pb) / 5 / 0.016
Mercury (Hg) / 0.20 / Not detected
Selenium (Se) / 1 / 0.170
Silver (Ag) / 5 / Not detected
16. / CO Toxicity / Carbon Monoxide (CO) – not observed approx 130O Centigrade
17. / Effect on Skin / No adverse effect
18. / Effect on Eye / No effect is observed because at normal temperature & pressure no gases was evaporated
19. / Effect on Inhalation / No irritation by inhalation at room temperature
20. / Effect on Plants / No adverse effect on plant
21. / Effect on Earth Worm / No adverse effect on Earth worm
22. / Effect on Aquatic Life / No adverse effect on Pond Fish
23. / Toxicity / Non-Toxic, Easily Bio – degradable & Environment Friendly.
24. / Flash Point / More than 158O Centigrade
25. / Flammability / Non flammable at normal temperature
26. / Flow Characteristic / Free Flowing Liquid above15 deg Centigrade
27. / Conductivity / Mixing with water shows Ionizing
28. / Surface Tension / 28+ 3 Dynes / Centimetre
26.45 on 1:1000 Result shows the tested sample
28.42 on 1:2500
32.09 on 1: 5000
29. / Aliphatic Test / Long chain Hydrocarbon
30. / Stability / Eighteen months from the date of manufacturing under storage conditions.
31. / Precaution for Use / May use Hands Gloves
32. / Transportation & Handling of Spills / Do not drop the plastic container from any height & save the container to strike with any harder materials such as stone, iron / metal rods, metal nails.
Do not Drink the Mixture of Water & DUSTRON
May Use Googols
33. / Container Disposal / Reused after thoroughly washed with water

ADVANTAGES

1.The compound DUSTRON - XT- COMPOUND is Non -ionic, Non-volatile, Non-flammable. So it does not harm for human health.

  1. Reduction of Water Consumption by approx. 40%
  1. Reduction of water

( a ) Electricity consumption by way of pumping.

( b ) Increases in the life of Lubricants-20 to 25 %

( c ) Increase in the of Spare Parts – 15 to 20 % due to increase in the life of

Lubricants and does not WEAR & TEAR due to dust free Environment.

4.Creates DUST FREE ENVIRONMENT thereby prevents dust inhalation by the workers.

5. A clean environment results in better production rate. The approaching road will be clear for vision and movement of Dumpers & other vehicles will be free and unrestricted thereby improving the Productive Capacity.

6.There is reduction in danger to the Human Health, which may not evaluate in terms of money. The different diseases depending upon the nature of dust brought almost under control. It bring indirect advantages such as :

(a) Medical expenses.

(b)Work does not suffer due to suffering from diseases of Mining / industrial personnel.

7.There is no chance of ACCIDENT of vehicle due to clean environment.

  1. Less servicing is required due to dust free environment.
  1. No complains for pollution from around the villages, towns, states & / or other concerned authority.

OUR MOTO DUST FREE ENVIRONMENT 1