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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
Formed through the mechanical breakdown of rocks, ores, and other naturally occurring inorganic materials, mineral dust is a dangerous source of occupational diseases and industrial accidents; therefore, it must be promptly and effectively removed from workplace air using specialized filtration systems designed to handle its insolubility and high abrasiveness.
Sources
What are rock dust minerals? These are not just wastes, but chemically active solid compounds ranging in size from fractions of a micron to hundreds of microns. They contain elements of the original rock, including quartz, feldspar, mica, calcite, dolomite, gypsum, as well as toxic minerals such as lead sulfide and mercury sulfide.
Mineral dusts are generated by processes involving the destruction, processing, and movement of rocks, minerals, and building materials, with most pollution produced during dry operations.
The mining industry is the primary source of mineral dust atmosphere, including emissions from crusher dust minerals, blasting, drilling, ore transfer, and quarry transport. At aggregate plants, the main sources of crushed stone dust are crushers, screens, conveyor transfer points, and loading operations. In this case, mineral dust entrainment and deposition must be performed directly at the contaminant generation point; otherwise, fine particles can disperse to surrounding areas, potentially leading to fines and operational shutdowns.
Mineral dusts are generated by processes involving the destruction, processing, and movement of rocks, minerals, and building materials, with most pollution produced during dry operations.
The mining industry is the primary source of mineral dust atmosphere, including emissions from crusher dust minerals, blasting, drilling, ore transfer, and quarry transport. At aggregate plants, the main sources of crushed stone dust are crushers, screens, conveyor transfer points, and loading operations. In this case, mineral dust entrainment and deposition must be performed directly at the contaminant generation point; otherwise, fine particles can disperse to surrounding areas, potentially leading to fines and operational shutdowns.
Mineral Rock in Industrial Production
Metallurgical plants specializing in blast furnaces, sintering, and steelmaking also generate significant pollution, with sources such as charge preparation, sinter screening, ore loading, and concentrate processing. The glass industry also has notable mineral dust aerosol sources, including the mixing of quartz sand and dolomite, component transportation, and cullet crushing. The specific glass dust hazards at these points, from silica classification to collector selection, are covered in a separate guide.
Harmful particles are also produced at cement, brick, and asphalt concrete plants during material processing. In the chemical industry, sources of mineral rock dust include the production of pigments, fertilizers, and silicate materials.
In some cases, not just mineral particulate matter, but organic mineral rock dust is formed, which poses certain challenges when choosing a cleaning method. It is generated during oil shale processing, peat processing, and at coal mines.
Mineral dust exposure is discussed in the following article.
Harmful particles are also produced at cement, brick, and asphalt concrete plants during material processing. In the chemical industry, sources of mineral rock dust include the production of pigments, fertilizers, and silicate materials.
In some cases, not just mineral particulate matter, but organic mineral rock dust is formed, which poses certain challenges when choosing a cleaning method. It is generated during oil shale processing, peat processing, and at coal mines.
Mineral dust exposure is discussed in the following article.
Five Mineral Dusts: Limestone, Dolomite, Clay, Sandstone, and Basalt
Methods of Removal and Control
Comprehensive protection against mineral fiber dust is achieved by combining source suppression and capture during formation. Fibrous glass dust follows the same logic, with fiber geometry adding capture problems of its own. Suppression involves the use of water sprays, which wet the particles, making them coarser and causing them to settle (in some cases, surfactants are added to the water); water injection into the rock or coal seam before mining begins; and foam isolation. The primary measure is aimed at preventing the formation of dry particles.
Already dusty air is purified by the following methods:
To prevent the spread of mineral dust aerosols, sealed enclosures are used at transfer and crushing points, equipment surfaces are regularly cleaned, and hydraulic hammers and other tools are employed where the fluid simultaneously breaks up the rock and binds the particulate matter.
Already dusty air is purified by the following methods:
- capture by the surface of a dry filter;
- capture by droplets in a wet scrubber;
- centrifugal ejection of particles against the walls of a cyclone filter, followed by sedimentation.
To prevent the spread of mineral dust aerosols, sealed enclosures are used at transfer and crushing points, equipment surfaces are regularly cleaned, and hydraulic hammers and other tools are employed where the fluid simultaneously breaks up the rock and binds the particulate matter.
Rock Cutting with Water Suppression
Overview of a Giant Bag Filter
Dust Collection Equipment
The mineral dust filter is selected based on the cleaning method. This may include:
- a bag filter – traps particles on the surface of a material shaped into bags mounted on metal wire frames;
- a cartridge filter – has a corrugated surface that captures small particles;
- a cyclone filter – creates a rotating flow, causing large particles to impact the walls under centrifugal force and fall into the collector;
- a wet scrubber – wets the particles with liquid droplets, thus ensuring their capture and subsequent removal along with the liquid.
Equipment selection criteria include: particle size, abrasiveness, and adhesion, flow temperature, and operational characteristics. For example, wet scrubbers require purification or disposal of the waste liquid. In the case of different particle dispersions, a two-stage cleaning system can be installed, where at stage 1 large particles are captured in a cyclone, and smaller ones are captured in a fine filter (bag or cartridge).
Examples of equipment selection based on the nature of the particulate matter are shown in the table below.
Examples of equipment selection based on the nature of the particulate matter are shown in the table below.
Disposal
When the captured particles are of no use or are toxic (such as galena, cinnabar, or asbestos particles), a disposal option must be considered. For asbestos, disposal planning must also address the dangers of asbestos dust created by re-aerosolization and inhalation during handling. The disposal method depends on the chemical composition of the particles.
Non-toxic waste is disposed of in specialized landfills. Before disposal, it is moistened to prevent the formation of a secondary contaminants cloud, mixed with binders, and the wet mass is leveled with bulldozers. A layer of soil or an insulating material (clay) is added on top.
If there are abandoned mines or quarries near the production facility, the rock mineral dust is disposed of in underground cavities. For this purpose, the captured waste is also mixed with water and pumped in.
For toxic substances, chemical stabilization is used, which involves mixing with lime, cement, bitumen, or polymer resins to form inert blocks, which are then disposed of at landfills. Bonding with the filler prevents toxins from entering groundwater.
Incineration is another option. It is used for coke, coal, shale particulate matter, and mixtures with high carbon content. The mixtures are injected into chamber or cyclone furnaces, where the organic matter is burned at 1000°C, and the resulting mineral residue is used as a concrete additive or landfilled.
Disposal steps:
Non-toxic waste is disposed of in specialized landfills. Before disposal, it is moistened to prevent the formation of a secondary contaminants cloud, mixed with binders, and the wet mass is leveled with bulldozers. A layer of soil or an insulating material (clay) is added on top.
If there are abandoned mines or quarries near the production facility, the rock mineral dust is disposed of in underground cavities. For this purpose, the captured waste is also mixed with water and pumped in.
For toxic substances, chemical stabilization is used, which involves mixing with lime, cement, bitumen, or polymer resins to form inert blocks, which are then disposed of at landfills. Bonding with the filler prevents toxins from entering groundwater.
Incineration is another option. It is used for coke, coal, shale particulate matter, and mixtures with high carbon content. The mixtures are injected into chamber or cyclone furnaces, where the organic matter is burned at 1000°C, and the resulting mineral residue is used as a concrete additive or landfilled.
Disposal steps:
- Determining the waste composition.
- Preparation for disposal: granulation, pelletizing (to prevent re-dusting).
- Selecting a disposal method and implementing it.
GIF Animation of Mineral Dust Collection and Disposal in a Bag Filter
Methods for Discharging Captured Products
Uses of Mineral Dust
Captured particles are not always waste. In some cases, they are a secondary product, as they have a specific value. For example, mineral wool dust can be remelted and then used to produce new wool. Alternatively, it can be used in alkali-activated binders. Another example: granite dust mineral is added to building mortars to improve the density and strength of products.
Gypsum rock dust minerals, generated during the production of gypsum materials and building mixtures, are captured and used as raw materials. If converted into the high-strength binder α-gypsum, they are used in the production of gypsum fiber panels.
Gypsum rock dust minerals, generated during the production of gypsum materials and building mixtures, are captured and used as raw materials. If converted into the high-strength binder α-gypsum, they are used in the production of gypsum fiber panels.
Turnkey Solutions for Quartz Dust Air Purification
We’ve prepared a handy cheat sheet and a detailed brochure to help you understand the different types of filters, their features, and areas of application.
Download the materials and explore the best solutions for efficient dust collection!
Download the materials and explore the best solutions for efficient dust collection!
View the cheat sheet for engineers
The most widespread dust mineral use is for soil remineralization and crop yield enhancement. This is explained by the fact that, when crushed, silicate rocks become a source of a wide range of trace elements that are lacking in arable land, as they are eventually washed out of the soil.
In metallurgy, rock dust mineral powder is used to produce zinc oxide, which is used in zinc smelters, while the iron-containing residue is used as an additive to blast furnace charge or sent to cement production.
The most valuable type of particulate matter used in construction is microsilica. When added to cement, it fills voids, increasing the strength of concrete. Bridges, high-rise buildings, and airfield slabs are built from this mixture. Basalt waste is also used in construction, forming mineral wool from it.
Stages of use:
In metallurgy, rock dust mineral powder is used to produce zinc oxide, which is used in zinc smelters, while the iron-containing residue is used as an additive to blast furnace charge or sent to cement production.
The most valuable type of particulate matter used in construction is microsilica. When added to cement, it fills voids, increasing the strength of concrete. Bridges, high-rise buildings, and airfield slabs are built from this mixture. Basalt waste is also used in construction, forming mineral wool from it.
Stages of use:
- Composition analysis is performed to determine further use.
- Mixed with binders and formed into briquettes.
- Processed if required or mixed with other components to produce the final product.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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