Wet Dust Control System Fundamentals

Wet systems are used for:

Dust Suppression
• Dust prevention: Humidity/moisture content in the material
is increased to prevent dust from becoming airborne
• Dust suppression/capture: Humidity/moisture is added to
the air to capture dust particles that are already airborne
These systems use spray nozzles to apply water and/or
chemicals such as wetting, foaming and binding agents
to dust particles. However, the system configuration
varies depending on the goal – dust prevention or airborne
dust suppression. Most operations require both prevention
Figure 1 Dust Prevention
and suppression to effectively control dust. See Figures 1, 2
Moisture is added directly to
and 3. It is important to understand the differences between the material to prevent dust
prevention and suppression systems to ensure proper from becoming airborne.
Airborne dust particles are
spray nozzle specification and operation.
also captured by sprays
during material unloading. Chute

Typical Operations Dust Dust

Suppression Suppression
Operations requiring dust prevention:
• Dumping
• Transport
• Transfer points
Figure 2
• Stockpiling/reclaiming After material has
been dumped into
In these operations, moisture can be applied to the
the hopper, sprays
material when it is stationary or moving or both. are used to suppress
the airborne dust.
Operations requiring airborne dust suppression:
• Conveyoring
• Shearing
• Continuous mining
• Crushing and screening
• Dryers
• Transfer points
Dust Dust
• Packaging/filling Prevention Suppression
Nozzles produce drops to collide with dust particles
that are already airborne. The moisture weighs the
particles down so they are returned to the material
source or ground.
As discussed previously, both dust prevention and dust
suppression may be required. The type of system will Figure 3
depend on the dust source and the stage in the Moisture is added to the material to prevent dust as it is transferred from
the hopper car to the hopper bin. Sprays are also used to capture airborne
processing operation. dust as the material moves down the conveyor line.

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Start with These Key Considerations
Fundamentally, wet dust control systems are the same – If you need to capture airborne dust:
all use water sprays. However, that’s where the similarities
What is the particle size of the dust?
end. System configuration starts by answering a few
critical questions. Dust capture is most effective when dust particles collide
with water drops of an equivalent size. (See page 8 for drop
size information.) Drops that are too large won’t collide with
If you need to prevent dust: the smaller dust particles and drops that are too small
What material are you adding moisture to? evaporate too quickly and release the captured dust
particles. See Figure 4. Understanding the particle size
Materials will respond to moisture differently. It is
of the dust is critical in effective system design.
important to understand exactly how much moisture
to add. Too little moisture means you’ll still have a dust You can use these general guidelines regarding dust
problem. Too much moisture and the integrity of the particle size. However, further research may be necessary
material may be compromised and quality issues depending on the material and stage of the material
will result. For example, when applying moisture to in processing.
ore, adding one gallon per ton provides adequate Particle diameter in microns:
wetting and does not cause process and production • Ground limestone: 10 to 1000 μm
problems. Too much moisture also means sludge
• Fly ash: 10 to 200 μm
and mud and frustrating, costly and potentially
dangerous maintenance problems. • Coal dust: 1 to 100 μm
• Cement dust: 3 to 100 μm
The material will also determine whether
chemicals should be added to the water to improve • Carbon black: 0.01 to 0.3 μm
suppression and/or lower overall application costs. • Pulverized coal: 3 to 500 μm
Coal, for example, repels water and usually requires
the use of chemical additives to increase absorption. Where is the dust?

Also, consider the processing stage. Most dust Capturing airborne dust with water sprays is most
particles created during breakage are not released effective in areas with little air turbulence. Depending
into the air. The dust stays attached to the surface of on the environment, enclosures may be required.
the broken material. Adequate wetting is critical to
ensure dust stays attached. Keep in mind that partially
processed minerals and coal may be more sensitive to
Dust
moisture than unprocessed material. Particle

Is the material moving or stationary?

Drop size and spray angle can affect surface
coverage when spraying stationary material.
Drop size and drop velocity affect coverage
when spraying moving material. These factors
Spray Spray Dust
must be considered when selecting and Droplet Droplet Particle
positioning spray nozzles.

Figure 4
If the drop diameter is larger than the dust particle diameter, the dust particle
will follow the air stream around the drop. (Shown left.) If the diameters of the
drop and the dust particle are comparable, the dust particle will follow the air
stream and collide with the drop. (Shown right.)

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Wet Dust Control System Fundamentals
General Wet Dust Control Considerations
Will the dust be returned to the product stream?
If so, the degree of wetting is especially important
to avoid quality problems.

Is rollback dust a problem?

Rollback dust usually comes from under the dumping
mechanism on front-end loaders, crushers, grinders,
cutting heads and entrances to scrubbers. Rollback
dust can be a significant problem and may require
a separate system for suppression.

What is the quality of the water?

Poor quality water can be very problematic in many
dust control applications. Strainers may be required –
even when using a clean water supply because
contaminants can be introduced to the water from
eroding pipes. Poor water quality will also require Is compressed air available?
more frequent nozzle maintenance, increase the Air atomizing nozzles mix fluid and compressed
nozzle wear rate and shorten service life. air to produce very small drops. Small drops evaporate
quickly and are desirable for use in operations where
wetting is needed but excess moisture cannot be
Where will the system be installed? tolerated. Small drops are also required when capture
of small airborne dust particles is required.
I f freezing temperatures are possible, heaters and
floor drains should be considered. Spray equipment
may need to be winterized. What is the spray solution?
If wind is a factor, nozzles that produce larger drops • Plain water systems are typically the least expensive
are better able to resist drift and should be used. and easiest to design and implement
• Adding surfactants to water will lower the surface tension
and allows better interaction between water and certain
How important is water conservation?
types of dust that resist water absorption
Water conservation is no longer optional in most areas.
• Foam systems use less water but usually require
It is important to specify nozzles that minimize overspray
compressed air
and water waste.
• Binders agglomerate particles together after the
Controls should be used to ensure the system is active only
moisture evaporates. However, binders can cause
when needed. Many options are available, ranging from
clogging and build-up on nozzles, conveyors and
simple solenoid valves for on/off control to sophisticated
other equipment. Water-soluble binders can cause
spray controllers that monitor a wide range of operating
environmental problems should run-off occur
conditions and make automatic adjustments.

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