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Dry-mist dust suppression system for dump trucks
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Dry-mist dust suppression system for coal-unloading tipplers at power plants and railway stations
A car dumper is a piece of equipment widely used in industries such as port operations, metallurgy, coal mining, and thermal power generation. In coal preparation plants, it serves as one of the primary pieces of machinery. It is also a large‑scale, high‑efficiency device designed to tip and unload bulk materials from open‑top railway cars. During the unloading process, substantial quantities of coal dust are rapidly agitated and discharged into a lower receiving hopper; in this operation, strong airflow separates fine particulate matter from the coal, which can severely pollute the surrounding environment and compromise both the service life of the equipment and worker health. Field measurements indicate that, during coal unloading, the majority of the coal dust generated is… 10 mu m with Respirable dust, with relatively high dust concentrations, can reach as high as 200mg/m3 . Guangzhou Aogong Spray Equipment Co., Ltd. — 15 With years of dedicated expertise in the spray‑drying industry and thousands of installation projects, we have developed solutions tailored to the operational characteristics of car dumpers in coal preparation plants. Based on an analysis of the dust‑generation mechanisms at these facilities, and taking into account dust‑removal efficiency, energy consumption, and the specific operational requirements of the dust‑control system, we have designed… Technical Solution for Dry-Mist Dust Suppression in Dump Trucks The key technologies have been optimized and refined, and the dust suppression performance has achieved further breakthroughs.
Composition of the dry-mist dust suppression system for train/thermal power plant tipplers:
1 ), Dry Fog Unit: Dry‑mist dust suppression equipment filters air and water, and, under preset air and water pressures, controls the opening and closing of solenoid valves via a programmed sequence to regulate flow rates. The filtered air–water mixture is then conveyed through dedicated pipelines to the dry‑mist nozzle assembly, where it is atomized into a fine mist. The system comprises an electrical control unit, a multifunctional control system, and a flow‑rate control system.
2 ), Automatic Control System: The automatic control system serves as the control center for the tippler’s dry‑mist dust suppression system, integrating a programmable controller, control circuits, protection circuits, a touch screen, and associated electrical components. It offers users two operating modes: automatic (remote) and manual (local). In automatic mode, the system can automatically receive remote trigger signals to start or stop the dry‑mist dust suppression equipment’s spraying function. In manual mode, operators can press the control buttons to initiate or halt the spraying process. Users can also, through… PLC The interface allows you to adjust the spray cycle and the intervals between pipeline sprays, among other settings.
3 ), Air compressor: The air compressor is used to regulate and stabilize the system’s air supply pressure. It is a screw-type, oil‑lubricated unit with a cabinet‑type design, offering high efficiency and energy savings, safe and reliable operation, durability, low noise levels, a compact structure, and simple operation. Equipped with microcomputer control, it features self‑diagnostic and protective functions.
4 ), Gas storage tank: The function of the air receiver tank is to regulate and stabilize the system’s air supply pressure. Since the air compressor generates a greater volume of air than the dry‑mist dust suppression equipment requires during normal operation, the tank stores this excess compressed air, thereby helping to balance and meet the equipment’s instantaneous air demand.
5 ), Water–Gas Distribution Box: By controlling it, the main water, gas, and electricity lines are connected to the dry-mist chamber. / The connection of the universal joint dry‑mist nozzle assembly, and according to site conditions, by… PLC Control implementation for each dry-mist chamber / Universal joint dry-mist atomizer assembly spray
6 ), Universal Joint Assembly: It receives air and water supplied by the dry-mist dust suppression system and converts them into particles with a diameter of 5~10 mu m Dry-mist dust suppression equipment Control commands direct the spray toward dust‑suppression points. The atomizing nozzles on the misting unit ensure uniform mixing of water and air, generating a fine dry mist that is dispersed outward. Each nozzle delivers a specific spray pattern, flow rate, and coverage area; when arranged in a uniform, tightly sealed array, they form a “mist wall” that comes into contact with airborne dust particles, causing them to collide, adhere to one another, coalesce, and grow in size. Under the influence of gravity, these agglomerated particles then settle, effectively achieving dust suppression.
7 ), Backwash Filter: A backwash filter is a precision device that uses a filter screen to directly trap impurities in the water, removing suspended solids and particulates, reducing turbidity, and purifying the water quality. It also helps minimize the formation of system fouling, biofilm, algae, and corrosion, thereby ensuring clean water and protecting the proper operation of other equipment in the system. Water enters the fully automatic filter housing through the inlet port, driven by intelligent control ( PLC 、 PAC ) Designed to automatically assess the degree of impurity buildup and send signals to the drain valve for automatic排污, the backwash‑enabled automatic filter addresses the limitations of conventional filtration products—namely, their limited dirt‑holding capacity, susceptibility to clogging by contaminants, and the need to disassemble and clean the filtration element without real‑time monitoring. Despite numerous drawbacks such as limited operational status, it features the ability to filter raw water and automatically clean and discharge contaminants from the filter element, while maintaining uninterrupted water supply during the cleaning and drainage process, achieving a high degree of automation.
8 ), Water–gas connection pipeline: The water‑air connection piping comprises pipelines of varying diameters, which are assembled according to specifications to link the dry‑mist dust suppression system, the dry‑mist assembly control cabinet, the air compressor, the compressed‑air storage tank, the water source, and other components, ultimately connecting to the dry‑mist assembly control unit.
9 ), Electric Heating and Insulation Systems: The electric heat tracing system (self-regulating type) is installed on the dry‑mist dust suppression unit, the dry‑mist nozzle assembly, and the water and air piping. When the ambient temperature falls below… +5 It automatically starts heating at ℃, and when the temperature exceeds +60 Heating automatically stops at ℃. In northern winters ( -30 The dry-mist dust suppression system can operate normally at a temperature of ℃.
Composition of the dry-mist dust suppression system for train/thermal power plant tipplers:
Application scope of dry-mist dust suppression systems:
● Dust suppression and cooling for construction sites with high dust levels, such as power plants, port coal terminals, railway freight yards, mines, coal mines, steel mills, and coal‑coking chemical facilities.
● Spray-based dust suppression and water‑spraying dust removal for large coal yards, coal piles, material storage areas, raw material yards, ore stockpiles, and transport vehicle lanes.
● Waste disposal sites, public spaces, and large-scale disinfection, deodorization, and disease prevention following natural disasters.
● Workshops and processing plants require humidification, cooling, disinfection, and other measures.
Demonstration of the Dust Suppression Effectiveness of Dry-Mist Technology in Train and Power-Plant Dumpers:
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