Dust Suppression with advanced Control System at Major US Recycling Firm
Dust is created at almost every step during the processing of powder and bulk solids. Dust is not only a nuisance, it is always a problem for the environment, and quite often, a health hazard. Following you can see, how an North-American recycling firm tackled this problem.
Padnos has been re-purposing recyclable materials for more than 100 years, serving industrial and commercial accounts throughout the U.S., as well as consumers in and around Michigan. With 21 locations, the company accepts a wide range of materials, including paper, plastics, ferrous and non-ferrous metals, such as iron, steel, stainless, copper, aluminum and brass. Among its primary customers are foundries and mills that re-use the valuable materials as feedstock for new products.
The firm has also made a significant investment in the processes and technology to recycle paper and plastics _ and more recently, electronics _ continuously building relationships with scrap dealers, logistics providers and buyers across the country. Now in its fourth generation of family management, the firm strives to leverage a century of scrap management expertise, implementing industry best practices for optimal efficiency, while maintaining the highest level of environmental stewardship.
As part of that philosophy, Padnos is constantly developing and refining its approach to fugitive material management, with a goal of preventing the escape of any dust or spillage that may be generated by its activities. In late 2012, the company researched equipment to deliver open-area dust suppression at its downtown location in Holland, MI.
“The site is about 29 acres,” explained Purchasing Director Bruce Karger. “We handle primarily metals at this facility, such as scrap from stamping plants and other metalworking operations, as well as peddler scrap from our smaller yards,” he said. “Most of it comes in by truck, and it’s moved by front loaders and cranes, though we also have rail and barge service.”
The loaders feed a shredder and a large shear, one built by Metso Texas and one supplied by Universal. Both have integrated dust suppression, but the outflow dries fairly quickly, especially in hot weather. Subsequent handling of the shredded material inevitably creates dust, which can migrate long distances if left unchecked.
Searching for the Right Design
Surrounded by businesses and neighborhoods, company officials wanted to take proactive measures to ensure that dust would not create a nuisance for the surrounding community or create a workplace hazard.
Therefore, after investigating several manufacturers and reviewing their equipment choices, Padnos selected a Dustboss DB-60 to deliver suppression over three processing centers, covering about three acres in all. “Other than basic material handling, the main dust-generating activities are shearing, shredding and bricking,” Karger continued. “Our goal is to ensure that airborne particles don’t leave the property.”
The DB-60 is supplied by Dust Control Technology (Peoria, IL). The atomized misting unit generates millions of droplets specifically sized to maximize dust suppression, and then launches them over large distances in an engineered air plume created by a powerful ducted fan.
A 25 hp electric motor gives the machine a reach of nearly 200 feet (about 60 meters), allowing the oscillating unit to cover an area as large as 125 000 square feet (more than 11 600 square meters) with a virtual dust blanket. Supplied with a 20-foot (6-meter) mounting tower, the DB-60 was installed atop a 10-foot (3-meter) concrete pedestal to increase its range and aiming ability even further. The control panel, booster pump and 3-way valve are located inside a shed for protection.
“We’ve used hoses and sprinklers in the past, and at times we’ve had our own water trucks on-site,” commented Superintendent Tim Driesenga. “But the suppression performance wasn’t what we had hoped for. We’ve also tried dust suppression equipment from other suppliers,” he said. “But when we compared results from the machines we had to the Dustboss, the DB-60 was far more effective, clearly a higher-quality design. It does a much better job of knocking down the dust and keeping it down.”