Rock Products

NOV 2012

Rock Products is the aggregates industry's leading source for market analysis and technology solutions, delivering critical content focusing on aggregates-processing equipment; operational efficiencies; management best practices; comprehensive market

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formance was so exceptional that the company decided to purchase the machine. In addition to the drastic reduction in airborne particles and reduced labor costs, the DustBoss has eliminated troublesome oversaturation of material. In fact, the production staff reports a noticeable improvement in product quality from eliminating the over‐watering common to hand‐held dust control efforts, which often create a muddy consistency that attracts contami‐ nants and complicates handling and processing. "Material purity is a critical issue, and you might not think dust control is part of that," commented Plant Manager Jim Petersen. "But dirt and other contaminants contribute to the formation of air pockets in asphalt, and can also cause crack‐ ing or pop‐outs on the surface of finished concrete." "Since it's portable and can be aimed as needed, the DustBoss provides flexibility when dealing with the wind," Petersen continued. "The unit's performance has definitely met and even exceeded our requirements. We've run the DB‐60 over the dustiest materials we process, and it's done exactly what we've needed it to." Linwood's facility is a full‐time operation, producing as much as 2 million tons of limestone products each year. The plant features four kilns, two of which are fully automated, and all processing is carefully monitored by com‐ puter control. " E The DustBoss has proven so efficient that Linwood estimates the unit paid for itself during the first month of use. other production facilities in the surrounding area must re‐ main within a specified range. Any time DNR air monitor readings exceed pre‐set limits, a shut‐down is mandatory until the 24‐hour averages return to acceptable levels. Finding a Solution Linwood officials visiting ConExpo/ConAgg last year came upon a booth hosted by Dust Control Technology where they saw a device called the DustBoss DB‐60. The portable sup‐ pression unit is designed with special atomizing nozzles to create a fine mist of water droplets that are the optimum size for dust control, launching them great distances with a power‐ ful 25‐hp fan. Capable of covering nearly 125,000 sq. ft. (about 1.16 hectares) when equipped with optional 359‐degree oscilla‐ tion, the DB‐60 looked like a promising solution, and Linwood decided to rent one on a trial basis. The unit was situated to cover the immediate area around the primary impact crusher, a Universal 4650 that reduces stone to 5‐in. minus. What had been a primary source of airborne dust quickly cleared up, eliminating the periodic work stop‐ pages on all but the windiest days, and Linwood officials saw production levels rise. Since implementing the control system, the facility has drasti‐ cally reduced shutdowns as a result of dust emissions, a wel‐ come change from the multiple incidents each month that were typical before the DB‐60 came on board. The unit's per‐ www.rockproducts.com Information for this article courtesy of Dust Control Technology. Linwood Lineage Linwood Mining and Minerals Corp. has been a producer of lime products, aggregates and calcium carbonate since 1944, and currently ranks as one of the largest limestone mining operations in the U.S. Linwood originally operated as an open-cut limestone quarry. However, because of de- mand for the uniqueness and high purity of the com- pany's limestone and exceptionally pure calcium carbonate, mining was extended to an underground oper- ation. As demand for Linwood's products increased through the years, the company introduced new equipment and tech- nology to accommodate expansion of the mines and meet customer requirements. With a confirmed reserve of more than 400 million tons, Linwood is assured of the ability to operate at high capac- ity well into the future. The company is uniquely situated in the Midwest, capable of shipping its products by truck, rail or barge. Dust Control Technology said that its DustBoss product line helps reduce labor costs versus manual sprays, freeing up manpower for more important tasks. The automated units also use less water than hoses and sprinklers, with some customers realizing payback in less than six months and netting an annual cost savings of more than $50,000. ROCKproducts • NOVEMBER 2012 25

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