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Dust management in the processing of dry bulk materials is a complex process. Dust control solutions must be flexible to ensure effective dust collection for different applications. Sometimes, for unusual materials and certain project requirements, controlling dust in the air becomes a real challenge.

An interesting example is the method of reducing dust emissions during the processing of metal silicon. Silicon metal is a unique product that is lumpy and abrasive. It is a hard and brittle crystalline solid used to make steel, solar cells and microchips. It occurs naturally in silicate minerals, including silica, feldspar and mica, which are the main components of common rocks such as quartz and sandstone. The mining and processing of these materials is related to occupational dust exposure.

Any dust can be harmful to your health, especially the silica found in rocks, sand, gravel and clay, of which quartz is the most common form. The use of silica-containing materials increases the risk of lung cancer. When embedded in human lungs, silica dust particles can cause permanent tissue damage. Long-term exposure may cause silicosis, chronic obstructive pulmonary disease and kidney disease. There is currently no cure for silicosis, and lung transplantation is the only option.

In the railroad facility in Carrollton, Kentucky, unloading silicon metal can generate a lot of dust, which endangers the health of employees.

The facility receives silicon metal in lump sizes approximately 1½ x 1½ x 1½ inches (sometimes larger in one direction) and feldspar particles approximately 1½–3 inches. Dealing with this unusually large and abrasive block product particles requires a unique dust removal solution. In addition, dust management tools need to be effective for high bulk densities of 56-72 pounds/cubic foot and dumping rates of 180,000-240,000 pounds/hour.

The solution for this project comes from Australia. The Burnley baffle is a dust suppression system developed by the Australian engineering company Mideco, which specializes in providing dust control solutions for mines, quarries and any commercial environment with dust problems. The Burnley baffle is Mideco's international patented dust suppression system, specifically designed to reduce the dust escaping from the dumping hopper and chute that handles dry granular bulk raw materials. When applied to the hopper alone, the Burnley baffle can eliminate up to 80% of the dust. Applying an additional dust collector directly to the hopper can suppress 100% dust. 

Why is the Burnley baffle so effective in this situation? First, the design of the system makes it a flexible tool for any size hopper. It consists of a set of modules with blades that fill the open entrance face of the hopper. During the loading or unloading process, the baffle strips the air entering the hopper from the product particles. This is because the air pressure on each side of the baffle is almost constant. The air is not enough to open the blade, only the product is allowed to enter, leaving dust under the blade. The system design adopts the principle of air flow, the installation is not complicated, and hardly any maintenance is required.

Second, the Burnley baffle is highly customizable and can meet the challenges of heavy-duty applications, such as silicon metal in this case. There are five different models to choose from. For this particular project, Model 5 is recommended, which is ideal for bulk materials composed of larger particles.

In addition, the system can be made of different materials when needed. For this application, the baffle is made of 16-inch thick Endura steel. They must be heavy and have a welded structure to withstand the high bulk density of such products for a long time.

These photos show the effectiveness and advantages of the Burnley baffle. In this case, no dust removal system is installed. However, the difference between "before" and "after" photos is obvious.

The project was a success in KY, and customer feedback was very positive. This is an example of the Burnley baffle simplifying the handling of dry bulk materials and protecting the health of employees. This is a complete dust suppression system, hundreds of which have been installed in Australia and around the world. They are currently installed in various facilities in Canada, the United States, New Zealand, Uzbekistan, China, the United Kingdom, and Ireland.

Burnley baffle can be used for ship unloading, railway unloading, truck unloading, bag unloading, roller unloading and front-end unloading transfer. Regardless of your company's dust problems and applications, the system can suppress up to 80% of dust without the need for additional dust removal equipment. 

Nunavut, Victoria, Australia 61 3 8873 0200 www.mideco.com.au

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