Dust suppression systems for crushing, conveying and stockpiles
Water spray, dry fog, fog cannons and capture: one system per emission point — crusher, transfer points, hoppers, stockpiles — built to run through winter.
Product Overview
Induscoat Solutions supplies, installs and commissions dust suppression systems for crushing plants, conveyor circuits, loading points and outdoor storage, in mines, quarries, cement plants, steel works and bulk terminals.
Dust is first a worker-exposure issue — respirable crystalline silica from crushing is covered by exposure limits set by the CNESST in Quebec, the Ontario Ministry of Labour and OSHA in the United States — and then a production issue: premature wear of bearings and belts, blinded screens, lost fines, visibility, neighbours. No single technology treats every emission point. A dump pocket, an enclosed transfer point and an open stockpile call for different answers, and the right answer is chosen by analysing the point: material, moisture, air movement, enclosure, temperature.
The technologies we supply
• Water spray and misting — spray bars and atomising nozzles at the crusher inlet, feeder discharge and chutes; the simplest system, chosen where added moisture is acceptable
• Dry fog — air-atomised water producing a fog of very fine droplets that agglomerates airborne dust without wetting the product; suited to enclosed transfer points, screens and crusher feeds where moisture must stay negligible
• Fog cannons — long-throw misting for open areas: dump pockets, stockpiles, truck and rail loading, quarry faces and ports
• Capture and filtration — hoods, ducting and dust collectors where the dust must be removed rather than knocked down, with the enclosure and sealing work that makes capture effective
• Containment — chute design, skirtboard sealing, dust curtains and settling zones at transfer points, the measure that comes before any suppression
Designed for a Canadian winter
A spray system that freezes in December protects no one. Our configurations include heat tracing, insulated and heated nozzle enclosures, drain-down on stop, heated water supply where needed and dry compressed air for dry fog — so that the system runs in January as it does in July.
How we work
We start with a survey of the emission points, then propose one technology per point with its water and air consumption, its effect on product moisture and its maintenance. Installation is coordinated with your shutdown window; commissioning includes before-and-after measurement where you want a documented result for your prevention programme or your client.
Challenges This Product Addresses
- Visible dust at the primary crusher and transfer points: complaints, reduced visibility, premature wear of bearings and conveyors
- Worker exposure to respirable crystalline silica above the permissible exposure values — a CNESST, Ontario and OSHA compliance issue
- Spray systems that freeze in winter, clog, or wet the product too much (blinded screens, lost fines, moisture in the concentrate)
- Dust collectors undersized or poorly connected: partial capture, saturated filters, emissions at the stack
- No measurement — impossible to demonstrate the system's effectiveness to the inspector or the client
Key Applications
- Primary crusher and dump hopper (trucks, loaders) — misting curtain and fog at the feed opening
- Conveyor transfer points, chutes and head pulleys — containment, dry fog, capture
- Screens, silos, truck and rail loading
- Outdoor stockpiles, haul roads and loading areas in quarries and bulk ports — fog cannons
- Cement plants and steel works — from the crusher to finished-product loading
Key Benefits
- One technology per emission point — spray, dry fog, cannon, capture or containment — chosen on the analysis of the point, not on a preference
- Built for the Canadian winter: heat tracing, heated enclosures, drain-down and dry compressed air, for a system that runs in January
- Water consumption and product moisture under control: suppression must not degrade screening or the product
- Before-and-after measurement and a compliance file to support your prevention programme
Industries Served
Guides and technical articles
- Dust control in cement plants: from the limestone crusher to cement loadingA cement plant has two dust problems in one: upstream, a quarry and crushing like any other; downstream, materials that cannot take water. The route point by point, and what works at each step.5 min
- Respirable crystalline silica at crushing plants: exposure limits in Quebec, Ontario and the United StatesCrushing rock that contains quartz produces respirable crystalline silica. What the regulations in Quebec, Ontario and the United States set, which positions are exposed and how to reduce exposure at the source.6 min
- Conveyor transfer point dust control: the 5 sources of dust and how to treat each oneA conveyor transfer point is the most repeated emission point of a plant — and the worst treated, because nozzles go in before anyone has understood where the dust comes from. The five sources, and the answer to each.7 min
- Dry fog vs water spray dust suppression: water use, product moisture, freezing, nozzle blindingBoth techniques put water on dust, but not the same way or in the same place. One wets the material, the other agglomerates airborne particles. What separates them — and what it changes for your screens, your lines and your water bill.6 min
- Dust suppression at the primary crusher and dump hopperThe primary crusher concentrates the most visible dust on a site: the cloud from the truck dumping, then the one from the crusher opening. The four emission points, the technologies that suit each, and what the unblocking boom changes.6 min
- Dust suppression technologies compared: water spray, dry fog, fog cannons, capture — which one for which emission pointNo dust suppression technology fits every emission point. A primary crusher, an enclosed transfer point and an open stockpile do not call for the same answer. The comparison, point by point.7 min