Application of Pulse Dust Collectors in Mining and Quarrying Industries

I. Industry Overview and Dust Characteristics

The mining and quarrying industry ranks among the most dust-polluted industrial sectors. Every stage—from extraction, crushing, screening, transportation, and loading to stockpiling—generates substantial dust. Particularly under dry operating conditions, dust concentrations are extremely high, particles are coarse, and specific gravity is elevated, causing severe equipment wear.

Common dust types include:

- Mineral dust (iron ore, lead-zinc ore, copper ore, gold ore, limestone, granite, etc.);

- Coal dust and quartz dust (high silica content, highly hazardous to human health);

- Concrete and cement dust (predominantly fine particles, highly airborne).

Particle sizes range from 0.5μm to 200μm, with respirable dust (PM10 and smaller) being readily inhaled by workers and posing significant health risks. Consequently, dust control in the mining industry is both an environmental requirement and a core occupational safety priority.

II. Dust Generation Stages and Dust Removal Challenges

Mining dust exhibits characteristics such as high concentration, large particle size, strong impact force, and high abrasiveness. It primarily originates from the following stages:

Crushing and Screening Stages

After processing through jaw crushers, cone crushers, and vibrating screens, raw ore generates significant airborne dust.

Characteristics: High dust concentration (up to 50–200 g/m³), coarse particle size, and strong impact force.

Belt Conveying and Transfer Points

Dust disperses severely during material drop or unloading, especially when wind speeds are high.

Loading and Stockpiling

Multiple dust emission points at stacker-reclaimers and loading ports affect a wide environmental area.

Drying and Grinding Sections

Fine dust particles readily become airborne, posing challenges for conventional dust collection equipment to capture efficiently.

Key dust collection challenges include:

Large particle size and high abrasiveness, leading to frequent filter bag damage;

Harsh outdoor installation environments with significant temperature fluctuations and high humidity;

High dust concentration requiring robust cleaning capabilities;

Variable airflow demands, necessitating system adaptability.

III. Application Advantages of Pulse Dust Collectors in the Mining Industry

1. High Adaptability and Dust Removal Efficiency

Pulse baghouse dust collectors utilize powerful pulse jet cleaning, ensuring stable operation even in environments with high concentrations of coarse particulate dust. Dust removal efficiency exceeds 99.8%, with outlet emissions below 30mg/Nm³.

2. Wear-Resistant and Durable Structural Design

The inlet features deflector plates and a settling zone, separating and settling large particles before they reach the filter bags, thereby reducing bag wear. The shell lining uses wear-resistant steel plates or ceramic linings, extending service life by 2-3 times.

3. Easy Maintenance and Low Operating Costs

The compartmentalized structure facilitates online maintenance and filter bag replacement. The automatic pulse control system adjusts cleaning frequency based on differential pressure, conserving compressed air.

4. Customizable for Specific Conditions

Pulse jet dust collectors can be flexibly configured as standalone units, small mobile systems, or large centralized systems to adapt to the complex spatial and airflow demands of mining sites.

IV. Structural and Technical Design Considerations

(1) System Composition

A typical mining dust collection system consists of:

Dust hood → Ductwork → Pulse-jet baghouse → Fan → Exhaust stack (or return air system).

Key design considerations for each component:

Dust hood: Should be positioned close to dust generation points with an airflow velocity ≥1.5 m/s;

Ductwork: Smooth inner walls with minimal bends to prevent dust accumulation;

Dust Collector: Preferably designed with bottom air inlet and top air outlet;

Fan: Equipped with variable frequency drive (VFD) to maintain stable system negative pressure.

(2) Filter Media Selection

Recommended filter media characteristics by operating conditions:

Common mineral dust: Polyester needle-punched felt – Economical, wear-resistant, high cost-effectiveness

High-abrasion dust (quartz, iron ore) Polyester membrane filter media / Aramid needle-punched felt Smooth surface, resistant to clogging

High-temperature conditions (drying systems) PPS / P84 filter media Withstands temperatures above 200°C, corrosion-resistant

High-humidity environments PTFE membrane filter media Excellent anti-condensation and anti-bag-clogging performance

(3) Cleaning System

Adopts air-box pulse-jet structure with cleaning pressure around 0.6MPa and uniformly distributed blow pipes. Offline compartmentalized cleaning mode prevents dust re-adhesion.

(4) Hopper and Ash Discharge System

Hopper angle ≥55° ensures smooth dust flow. Equipped with star discharge valves or screw conveyors at the bottom for continuous ash removal.

V. Typical Application Cases

Case 1: Dust Removal for Limestone Mine Crushing System

The plant originally used cyclone dust collectors with efficiency below 85%, resulting in severe dust leakage.

It was later replaced with a 24-bag pulse jet dust collector, controlling filtration velocity at 1.0 m/min and utilizing membrane-coated polyester filter bags.

Operational Results:

- Emission concentration ≤ 25 mg/Nm³;

System resistance stabilized at 1100Pa;

Filter bag service life exceeded 30 months.

Case 2: Dust Collection in an Iron Ore Screening Workshop

Due to large particle size and high abrasion, the system employed aramid filter bags with inner wear-resistant lining plates. After 2 years of continuous operation, filter bag integrity remained at 95%, with differential pressure consistently below 1300Pa.

VI. Key Operation and Maintenance Points

Regularly inspect the pulse-jet system: Nozzle blockage or insufficient air pressure may result in incomplete dust removal.

Keep ash hoppers unobstructed: Regularly discharge ash to prevent bridging.

Monitor filter bag wear: Pay special attention to inlet areas and beneath deflector plates;

Prevent rainwater ingress: Install rain covers and drainage systems for outdoor units;

Implement variable frequency drive (VFD) control for fans: Automatically adjust air pressure during flow fluctuations to extend filter bag lifespan;

Regularly measure differential pressure and emission concentrations: Address anomalies promptly through maintenance.

VII. Environmental Protection and Economic Benefits

After adopting pulse jet baghouse dust collection systems, the mining industry achieves the following outcomes:

Dust emissions reduced by over 90%, meeting the “Emission Standards for Mining Enterprises”;

Workshop dust concentration lowered below 5 mg/m³, satisfying safety production requirements;

Extended equipment lifespan by reducing dust-induced wear on bearings and belts;

Recovery of usable powder materials, minimizing material loss;

Enhanced corporate environmental reputation and safety rating assessments.

VIII. Conclusion

In mining and quarrying operations, high dust concentrations and severe abrasive conditions impose stringent demands on dust collection equipment. Pulse jet baghouse dust collectors have emerged as the mainstream solution for mining dust control due to their high filtration efficiency, robust construction, and simplified maintenance.

Looking ahead, advancements in intelligent monitoring and wear-resistant filter media will enable mining dust collection systems to achieve extended lifespans, low energy consumption, and unmanned operation. This will provide a solid foundation for green production and sustainable development in mining enterprises.