Do you know that PM 10 dust in the workplace is a great hazard to most industries? The large amount of dust generated during handling and manufacturing operations can cause serious health hazards to your workers. If left untreated and dispersed in the air, dust can cause serious health risks, such as respiratory diseases. In addition, your industrial facility may also be subject to subpoenas and fines.

Here are how various industries produce dust:

●Coal Mining

Coal dust is the main cause of corrosion in all underground mines. It is produced by breaking and crushing coal which initiates chemical reaction with air creating its oxidizing atmosphere, where iron (steel) oxidation occurs, leading to rusting of structures like conveyors, gantries, chutes, etc.

●Construction Industry

The use of dry powder blaster for removal of paint from steel structures causes the emission of high concentrations of irrespirable dust, which contains extremely hazardous particles like iron oxide (rust). These particles can easily pass into the lungs, initiating respiratory diseases like Silicosis, emphysema, bronchitis, etc. Lead paint should be removed mechanically first before blasting as lead fumes/dust are hazardous.

●Cement Industries

The cement industry gives out harmful dust because of various activities like blasting, cutting, grinding, crushing, and drilling. These activities result in the emission of fine respirable dust (diameter less than 10 microns), which is known to cause cancer and complications like bronchitis and asthma because the particles (dust) bypass the nose-throat filter and reach deep into the lungs where it can do serious damage to one's health. For these reasons, cement industries should be located away from residential areas.

●Glass Making

Glassmaking or glassworking produces silica as a by-product which causes Silicosis. This respiratory disease is incurable as they cannot recover once injured by this dust exposure. Protective masks should be used while working on furnaces, polishing, and cutting glass.

●Stone Cutting/Grinding

Cutting or Grinding of stones also emits respirable dust particles, which are hazardous, especially when the stone contains crystalline quartz (silica). Respirable dust exposure causes Silicosis, which is incurable as the lungs cannot recover once damaged by this dust exposure. Masks should be worn during stone cutting or grinding.

●Wood Industry

Wood industry cause inhalation exposure to wood dust composed of small particles (particles less than 10 microns in diameter) that easily pass through nose-throat filter deep into lungs where they can do serious damage. The most common diseases associated with wood dust exposure include woodworker's pneumoconiosis and asthma.

The best way to solve this problem and suppress the large amount of dust generated in industrial activities is to install a high-pressure misting system. Let's understand the science behind the high-pressure misting system first.

Working Principle Of Misting Systems

The high-pressure main machine purifies and pressurizes the water to above 4-6MPa, and the water is hit by the special nozzle through the tube to change the velocity distribution of the jet cross-section so that the large particle droplets are broken and atomized into small particles. Under the action of aerodynamic force, the particles are further materialized into countless "fine mist" with a diameter of 10-20 microns. The "fine mist" floats in the air and absorbs the dust in the air, and changing water from liquid to gaseous state, which increases the humidity in the air.

Composition Of Misting Systems

1. Main parts:

●High-pressure main machine

●Special dust suppression nozzle

●Mist Fittings: Including nozzle base, elbow, tee connector, straight connector, valve, etc.

●Pipe: 304 or 316 stainless steel material

2. Other Parts:

●Filtration system: Three-stage filtration or stainless steel fine filtration

●Dosing device: Adding chemicals

●Water tank: Store a large amount of water

mist fitting (1)mist fitting (2)

Advantages Of The Misting Systems

The misting system has established itself as a reliable method in suppressing dust. Its advantages are highlighted below:

●Ease Of Use

The droplet size of fog used is about 10 to 20 microns (10-20 thousandths of an inch). That's smaller than most other techniques, such as water blasting or sprinkling that could raise the dust level back into the air again. This will lower labor costs since you can operate it without an extra workforce, unlike conventional methods where two people must manhandle each nozzle to spray water while monitoring the work site simultaneously.

●Safety

The water used in a misting system is safe for people and the environment. The droplet size of fog is small, which means less splashing on workers or onto adjacent properties. Compared to common methods like lumbering or power sweeping, there are no eye irritations. There are also no health problems since operators aren't exposed to toxic substances like chlorine bleach, ammonia, hydrochloric acid, boron minerals, and others normally associated with using water to suppress dust.

●Durability And Efficiency

The design of our misting systems allows them to operate continuously for several years resulting in lower maintenance costs compared to mechanical-driven systems. The fog system is most efficient since it can cover up to 100,000 SF on flat terrain. The misting nozzles are also durable and made from stainless steel with ball joints for easy maintenance.

●Effectiveness

Controlling dust with the misting system has been proven to achieve results that other methods cannot efficiently. It's able to suppress dust while providing an environment conducive to work. After misting, you will notice all the areas covered by the fog will have less visible dust. Depending upon atmospheric conditions, this could be within minutes or hours after implementation.

●Low Water Use

The fogging system is designed so optimum pressure can be achieved throughout the entire height range. It can control a 500-4000 square space for spraying. According to the requirements of different areas, the water flow rate can be adjusted from 100-1600 Kg/H according to the needs. Considering the flow rate of a conventional atomizing nozzle, the water consumption per hour is only 2.5L/H.

●Low Maintenance Costs

After installation, misting systems require very little maintenance. On average, the misting system has far fewer components than most other types of dust suppression equipment. There are no nets, hoses, or fittings to maintain, as some sprayer trucks may need.

●Lower Operating Costs

The misting systems can be operated more efficiently compared to other methods like dust palliatives (water, lime, etc). The fog emitted from our misting nozzles contains small droplets that will not wet or damage equipment, tools, or other items within the misted area. This makes it possible to operate without delays.

●Unlimited Operating Range

Almost all misting systems can be used either inside or outside, depending on the type of project you have. It allows for speed and flexibility with little to no disruption to work schedules.

●Provides Immediate Results

With other types of suppression, you need to wait up to 24 hours for your working environment to become clear again, but with a misting system, you can see visible results in less than an hour.

●No Residues Left Behind

Other types of dust suppressants leave behind residues, making it difficult for equipment and machinery to work properly. This is because the residues are usually made up of harmful chemicals that seep into your equipment, causing slow functionality or even electrical malfunctions.

Application Of The Misting Systems In Industries

Here is information on how various industries can apply the misting system to suppress dust:

●Metal Production

Metal dust particles contain harmful chemicals that may contaminate the environment. The dust can cause health problems for workers if they are not properly contained or eradicated. Ventilation and filtration systems alone cannot remove all aerosolized metals from work atmospheres. Metals must be kept moist to avoid recontamination of rooms, storage tanks, and pipelines from the air once the project has been executed.

In addition to this protection function, a wet surface can better resist corrosion due to its coating of oxide compounds formed by water electrolysis. An anode and a cathode of identical material can be placed parallel to each other. Water mist will cover the surface and protect it from atmospheric oxygen so that no corrosion will occur.

●Mining

There are adverse health effects on the mining industry workers as well as on the environment. Exposure to harmful materials such as arsenic, nickel, lead, zinc, or even uranium can cause health effects. Misting systems provide protection against alkaline dust (e.g., sodium compounds) that tend to produce alkali lakes when they react with water. Moreover, some metal dust may contain metals that can be lethal when in contact with water.

●Powder Production

Apart from the operations in metal production, misting systems play a major role in maintaining workers' health by removing harmful chemical particles from the air they breathe. In addition to this function, environmental protection is also needed because some powders may also react with atmospheric moisture and produce explosive compounds such as nitrides or carbonates.

●Cement Production

Misting helps with dust separation before entering cyclones for fine particle collection. Misting system also helps cement producers reduce clinker dust emissions during cement grinding processes leading to lower environmental pollution. Improved worker safety due to the reduced risk of inhaling toxic solid aerosols that may arise in the grinding and bagging processes is another benefit.

●Phosphate Manufacturing

Misting helps in dust separation, oxidation, and consequent filtration to avoid consequential problems with phosphate products that can cause damage to crop or animal growth when used improperly.

The process of installing the misting system is not easy, and setting everything up correctly is time-consuming and challenging. The best choice is to be guided by an experienced professional. It is recommended to look for a misting company with many years of installation experience. Nebufly, which has been established for more than 10 years, provides customers with first-class and high-quality service. We can quickly and effectively establish a perfect misting system for any private or commercial space. Please don't hesitate to contact us by email or phone.