CONTINUING EDUCATION PROGRAM: SHORT TERM COURSE

SURFACE MINING HAUL ROADS AND OFF HIGHWAY TRUCKS

Haul road dusts

Prof. Khanindra Pathak

Mining Engineering Department
IIT KHARAGPUR
After going through this lecture you will be able to

• Identify the causes of haul road dusts

• Categorize the dust palliatives commonly used in different dust
suppressing environment based on their characteristics
• Discuss applicability of water for effective dust suppression with
associated problems and remedies
• Examine the selectivity of different dust suppressing agents and develop
selection guideline
FACTORS THAT GENERATE HAUL ROAD DUST

• Vehicle speed
• Number of wheels per vehicle
• Number of vehicles
• Vehicle weight
• Particle size distribution (gradation) of the surface material
• Restraint of the surface fines (compaction, cohesiveness/bonding,
durability)
• Surface moisture (humidity, amount of precipitation, amount of
evaporation).
Dust generation per vehicle mile traveled as a
function of speed (EPA, 1995)
Relationship between speed and fugitive dust from a grave road
(Roberts et al., 1975)
Dust Palliatives
 Dust palliatives are substances applied to a road surface to
reduce airborne dust.

Important parameters of using:

• Type of materials
• Frequency of application based on road usage- every few hours on a busy mining
haul road, or every few years on a forest road with little traffic.
Methods for haul road dust control

• Water application
• Salts—hygroscopic compounds such as calcium chloride, magnesium chloride,
hydrated lime, sodium silicates, etc. Salts increase roadway surface moisture
by extracting moisture from the atmosphere.
• Surfactants—such as soaps and detergents. Surfactants decrease the surface
tension of water, which allows the available moisture to wet more particles
per unit volume.
• Soil cements—compounds that are mixed with the native soils to form a new
surface. Examples are calcium or ammonium lignon sulphonate, portland
cement, etc.
• Bitumens—compounds derived from coal or petroleum such as coherex
peneprime, asphalt, oils, etc.
• Films—polymers that form discrete tissues, layers, or membranes such as
latexes, acrylics, vinyls, fabrics, etc.
• Soil cements, bitumens, and films—These form coherent surface layers that
seal the road surface, thereby reducing the quantity of dust generated.
 KINDS OF DUST PALLIATIVES
Big Business: “fugitive dust” must be controlled at many construction and
industrial sites across the nation

• water,
• water absorbing products, (deliquescent/ hydroscopic)
— calcium chloride brine and flakes
— magnesium chloride brine
— sodium chloride (salt)
• Organic petroleum products,
— asphalt emulsions
— cutback asphalt (liquid asphalt)
— dust oils
— modified asphalt emulsions
• organic nonpetroleum products,
Basic categories — animal fats
— lignosulfonate
— molasses/sugar beet
— tall oil emulsions
— vegetable oils
• electrochemical products,
— enzymes
— ionic products
— sulfonated oils
• synthetic polymer products: polyvinyl acetate, vinyl acrylic
• clay additive: bentonite , montmorillonite.
How much water can safely be applied to a haul road?

 Safe water application rate, expressed as mm/m 2, so that a

minimum level of grip in the road is maintained after watering

How to balance  dust suppression and overwatering?

 Utilising a combination of the Global Road

Friction Risk Model, mobile dust monitoring
technology and a measurable water truck spray
control system can remove the guesswork of
the current operation methods – resulting in a
safer haul road with less dust and a more
efficient use of water.

 The ability to manage and consistently apply the correct amount of water to a haul
road can result in improved  productivity and safety, and significant savings. 
ECO Spray Delivery System, uses truck ground speed inputs to
provide an inherently safe water delivery spray control system for
large off highway water trucks. As the name suggests ECO spray uses
advanced electronic controls with parameters which control the
application of both pump speed and double acting hydraulic spray
head activation.

Australian Diversified
Engineering (ADE) Pty Ltd, Aspley,
Australia.
Characteristics of palliatives

While adopting any palliatives one should be careful about its characteristics

• Physical state- liquid, or powder.

• Water solubility
• Re-workablility of the rod surface after it is treated with the
palliative
• Depth of application i.e, e to what depth the palliative need to be
incorporated
• Washability or erodibility rate
• Frequency of re-application need
• Corrosion effects to equipment or vehicles
• Required precautions for using the palliative
• Hazard potential to humans when used according to the
instructions
• Hazard potential if no one reads the instructions
• Effect of washed or eroded palliatives on surrounding ecosystems
• Decomposition potential and nature of the decomposition
products
Principle of dust suppression

Dust suppressants work by reducing the ability of the surface particles to be

lifted and suspended by either vehicle tires or wind. This is done by:
• agglomerating the fine particles,
• adhering/binding the surface particles together, or
• increasing the density of the road surface material.
Working principles of Palliative
Increasing Moisture Content in the surface of dirt roads can keep the
dusts bound
Moisture causes particles to stick together. The moisture content of dirt roads can be
increased:
• through spreading water
 moving water to unpaved roads can be a problem.
 When water can be applied, it only provides a short term reduction in
dust.
 Regular, light watering is better than less frequent, heavy watering.

• application of salts which attract water (deliquescent salts ).

 The application of deliquescent salts to road surfaces can
control road dust. A deliquescent salt, like calcium or
magnesium chloride, absorbs water from the air.
 Soils treated with deliquescent salts have a higher water
content than untreated soils.
 Slippery wet roads and vehicle corrosion are disadvantages
of salt application.
 Also, rainfall eventually removes salts from the roadway.
 Binding Particles Together
Chemicals which bind fine particles together or onto larger are of various types:
• petroleum-based,
 Petroleum-based Binders e.g. emulsified asphalts, cutback asphalt coat particles
with a thin layer of asphalt increasing particle mass and decreasing the chance of
becoming airborne.
 Emulsified asphalt is a mix of asphalt and water which penetrates road surface dirt.
This works well when the asphalt is mixed into the top inch or two of road surface
with a grader.
 These products can contaminate waterways due to runoff and are not prescribed.
• Organic Nonpetroleum Dust Suppressants
 Lignosulfonates found when lignin is extracted from wood. The natural polymer
Lignin can bind soil particles together. Lignin occurs in solution with sodium,
calcium, ammonium, or magnesium bisulphate.
 Resins made from combining lignosulfonates and additives can neutralize adverse
effects. Lignosulfonates are water soluble and can move out of, or deeper into, a
roadway surface with rainfall.
 These products corrode aluminum unless calcium carbonate is present.
Lignosulfonates work best with fine dusts such as clay particles having a high
plasticity in dry environments..
Binding Particles Together

• electrochemical stabilizers,
 Electrochemical Stabilizers include sulphonated petroleum, ionic stabilizers, and
bentonite.
 These products neutralize soils that attract water and allow bonds to form
between particles.
 Electrochemical stabilizers need to be worked into the road surface, requiring
equipment that may not be available with the mining cpmpany.

• synthetic polymers.

 Synthetic Polymer Products like polyvinyl acrylics and acetates bind soil particles
and form a semi-rigid film on the road.
 These products are either liquids or powders that are mixed with water and are
applied in liquid form and require drying.
 Traffic should be diverted from treated areas until after drying - which can take
12 to 24 hours.
 Synthetic polymer products have been used for dust control and improved soil
strength on a number of airfields in Northern Canada and Alaska.
Guidelines for cost-
effective selection
and use of dust
palliatives.
Palliative Selection Table for Palliatives Used in Alaska (adapted from Jones and
Surdahl, 2004)
 Dusts on Coal Mines Haul Road

Test results of Surface Coal mining dust samples (Mandal et al, 2012, CMFRI)

• pH : 5.1-7.7.
• Moisture 0.5-3.0%,
• Ash: 45-76%
• volatile matter: 12.6-20.0%
• fixed carbon: 10.2-45.3%
• water-holding capacity21.17-31.71%
• bulk density 1.15-1.70
• specific gravity 1.73-2.30 g cm(-3)

• it is suggested that coal dust from haul and transport roads of mining areas
can be effectively collected and used as domestic fuel.
Haul Road Dusts in Iron Ore Mines

Concentrations (μg m−3) of trace elements at Noamundi’s haul road dusts

Zinc 13.92–16.34
Copper 0.06–0.09
Lead 0.71–0.79
Manganese 0.14–0.15
Cobalt 0.08–0.11
Nickel 0.15–0.17
Cadmium 0.003–0.004
Iron 390–401.20

Major sources of dust

• vehicle exhaust,
• metallic corrosion
• galvanized material
• tire wear
• zinc compound in rubber material
Newtrol™
Glycerin-Based Dust Suppressant

Formulated with renewable resources enhanced to

control dust, Newtrol agglomerates loose particles and
holds moisture on the surface thereby reducing dust on
roads and open areas. Newtrol-treated roads stand up to
heavy traffic on community roads, gravel runways and in
other sensitive environments.

An alternative to corrosive chlorides, Newtrol comes in

concentrate or solution formulations for an easy load-
and-go application process, which you can do on your
own or which Midwest can manage.
Newtrol is a high-performance, glycerin-based dust
suppressant with humectant characteristics that
make it effective for dust suppression

Enhance road performance

The firmer, more stable, dust-free road surface resulting from treatment with
Newtrol reduces the need for frequent road repair. The surface toughness
resists the tendency of dirt and gravel roads to form wash board ribbing and,
therefore, requires less frequent or no ongoing grading.
The safety factor
Newtrol-treated unpaved roads are safer than untreated roads, on which
visibility-impeding dust clouds are inevitability. Applied properly, Newtrol is
non-toxic and will cause no harm to surrounding foliage and surface water.
Other Commercially available dust controlling agents

Soil-Sement Engineered Formula is a special product that

creates an engineered stabilized 7 to 25 cm layer with unique
superior strength for roadways. Soil-Sement Engineering
Formula prepares subgrade for chip seal, paving, and milling
applications.

Soil-Sement Engineered Formula road construction and

stabilization system creates an impenetrable, durable surface with
superior compressive strength
 Dust suppression system
such as this AkkuaJet
model can use remote radio
controls, giving the load
operator complete control
over dust management.

The variable height hydraulic

mast affords tilt and 360° head
rotation throughout its 5.5m
working height. Power comes
from an on-board diesel gen-
set giving electrical power to run
the pumps and motors needed to
create 15bar of working pressure Comac Environmental UK, models:
for the dust suppression system. AkkuaJet 35S and 65S,
Available with crawler undercarriage and
trailer-mount formats.

The 35S and 65S use a ring of nozzles contained in a boom-mounted fan system which
blasts atomised water over a distance of 35m and 65m respectively.
The fully-programmable AkkuaJet can also be equipped with a remote radio control system
enabling the loader operator to constantly adjust the machine’s position and output to suit
changing wind direction and dust creation.
SOIL SEALANT

Alternative to using water as short-term solution for dust

suppression(due to evaporation) is soil sealant. One such
product is Top Seal marketed by  Soils Control
International (SCI).
Top Seal is a soil sealant and stabiliser that can be used to coat a haul
road.

• Provides greater stability to the surface to prevent run-off and

erosion.
• It is mixed with water and applied to the scarified road, to allow
the liquid solution to penetrate and mix into the soil.
• Manufacturer suggests that three applications are generally
required to give the desired level of soil bonding.

The annual cost of haul road dust control with exisiting system should
be properly evaluated to asses the long term costs of introducing new
system. The manufacturer claim of cost savings will depend on
several factors and may vary mine to mine.
 Protect persons from dusts

Dust masks (also known as

filtering facepiece
respirators)

Air Helmet with batterypowered fan,

filtering system, and face visor
providing protection for the head,
lungs, and eyes within one unit
 Summary

Dust control on haul roads are important and must be well planned
and performed based on the existing conditions.

Land clearing Activities

Control Method Description
Watering Application by means of trucks
and/or hoses during land
clearing operations
During periods of high winds 1. Apply chemical stabilizers
per manufacturer’s
. 1. directions, and prior to
expected wind events.
2. Apply water as necessary,
and prior to expected wind
events.
3. Stop work activities
temporarily
Dust control for Earthmoving Activities
Dust Controls at
Haul Roads and Shoulders
 Description: Water cart spraying water on haul road
with loaded and empty haul trucks on
background.
Copyright: Peter Robey
Collection(s): •General Mining & Resource

http://www.miningphoto.com/details/1593/
water_cart_spraying_water_oin_haul_road_with_loa
ded_and_empty_haul_trucks_n_back

A water truck sprays roads to prevent dust at Atlas Iron Ltd.'s

Pardoo mine site in Pardoo, east of Port Hedland in the Pilbara
region of Western Australia, on Wednesday, June 23,
2010Photographer: Carla Gottgens/Bloomberg via Getty Images
 rear fantail sprayers, spray bars, 2" fire
nozzles,
tank mounted water cannons, rear flooding
dump valves, and pump through valves
 the Cat WDS is designed to put water to
the ground in a controlled, intelligent way

The Cat® 777G Off-Highway Truck with integrated Cat

Water Delivery System is increasing safety and
productivity at the Kinross gold mine in

Cat® Water Delivery System

The ability to manage and consistently apply the correct amount of water to a
haul road can result in improved productivity and safety, reduced maintenance
and significant savings to companies.