Dust Suppression via Remote Control

Recycling & Recovery

Dust Suppression via Remote Control

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.
(ed. WoMaMarcel - 16/12/2014)
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From the time of its initial arrival, the Padnos team was pleased with the results of using the Dustboss. “The performance of this design is better than any method we’d tried in the past, and eliminating the manual spraying presented immediate labor savings for us,” Driesenga said. Though it’s one of the largest models DCT offers, the DB-60 uses less than 24 gallons (90.85 liters) of water per minute, even with the booster pump raising pressure to 160 psi (11 bar).

Extended Remote Controls Capabilities

The unit was originally supplied with four optional remote controls, giving loader operators the ability to turn the unit and the oscillation on or off at any time. The oscillation range, however, was only programmable at the panel. Although the system performed well, operators noticed an opportunity to even better serve the unique layout and work flow at the Holland plant, so they contacted DCT to discuss some possible modifications to the system.

“We felt that we could make dust control even easier and more efficient for the operators who are moving our material,” said Driesenga. “The easier the equipment is to operate, and the more efficiency we can build into the dust management process, the more likely that the equipment will be used, and used correctly,” he added.

During the initial meeting, Driesenga explained that loading and unloading could take place at nearly any point within the roughly 3-acre area, and the 359° oscillation was a key to reaching those activities. But the relatively slow oscillation speed prevented a quick rotation of the barrel to focus on an arriving truck. Operators had to wait for the machine to oscillate to the required spot.

The big question was whether DCT could redesign the unit to reach any point on the oscillation arc in 30 seconds or less, AND build the control capability into the remotes that the company already had. Adding the ability to set the arc remotely would also be a huge bonus, relieving operators from having to visit the control panel.

“The first reaction we got was ‘We’ve never done that before,’” recalled Karger. “But no sooner was that said, then the DCT team got busy with us to figure out exactly what features we needed and how it could be done. We were extremely impressed with the technical assistance they provided in developing the concept and turning it into a working reality.”

Engineers from DCT decided that they could achieve the desired repositioning speed by replacing the fixed-speed oscillation motor with one that turned approximately 4x faster, coupled to a variable-frequency drive (VFD). To avoid having to ship the unit back to IL for the revisions, DCT personnel performed the gear motor change-out, panel modifications and VFD installation on-site.

While maintaining all existing controls on the remotes, DCT technicians also added the ability to select from eight pre-set oscillation ranges, which could be programmed by operators from the modified panel with its touch-screen display. Finally, they added a “Jog Left/Right” switch and a “Home” button to the remotes for quick repositioning.

“With the modified remotes, we have much more versatility in aiming the Dustboss and quickly bringing it to the exact location needed at any given time,” observed Driesenga. “And the oscillation arc can be changed even while the oscillator is running.”

Constant air monitoring at the Padnos site have confirmed the machine’s effectiveness, helping the company to remain in full compliance with air quality regulations. “We recently had an inspector review our operations this past summer, and he commended us on our dust control measures,” Driesenga concluded. “The results were better than he expected.”

Added Karger: “I feel like these are the tools that enable us to do a better job of preventing dust from leaving our property. For us, it’s taking our dust management to the next level. In fact, we have plans in place for another unit.”

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