Case Study: Scrapyard Shredder Dust Control Boosts Production 30 Percent

Dust Control at Metal Recycler Shredder

One of the largest metal recyclers in the Midwest is knocking down shredder dust with a pair of dust suppression systems, helping operators to increase production by as much as 30 percent.

"We recognized that we needed to go beyond the integrated injectors and closed-loop system of the shredder, so we began researching additional mitigation techniques."

A spokesman said the equipment is so effective that the company can now run its shredder line even on days when dusty source materials and unfavorable wind conditions might have prevented operations in the past.

The powerful DustBoss dust suppression machines were also a key element in securing EPA approval for a new shredder. Successfully meeting the requirements allowed the facility to begin processing automotive scrap, a market in which it could not be competitive using its existing equipment.

In addition to aiding the permit process, the company estimates the benefits have been so significant that the dust suppression system paid for itself in about six months.

The scrapyard dust control plan

The recycling facility is a privately owned scrap buyer and recycler processing about 30,000 tons per month of both ferrous and non-ferrous scrap.

The firm recycles aluminum, stainless steel, copper, brass, allows and all grades of iron and steel. The company accepts aluminum cans, appliances, radiators, junk cars, trucks, construction steel and siding from businesses and consumers.

About 1,500 tons per month is municipal debris (incinerator scrap), which has a high ash content and large potential for dust generation.

In late 2008, company officials wanted to gain process efficiency and broaden recycling capability by installing an American Pulverizer 80x104, a 4,000 HP machine capable of shredding 100+ tons of metal per hour. The unit features water injectors to control dust and prevent explosion hazards, as well as a closed-loop conveyor system to mitigate dust when materials go through the separator.

Dust Suppression at Metal Recycler

In addition to greater shredding ability, the AP design would allow the firm to eliminate shearing and baling of materials that could not be shredded with its existing production line.

"To obtain EPA approval to install the new equipment, we had to satisfy specific requirements during the permit application process. We also worked with a local group to develop a dust control plan," said the Shredder Operations Manager. "We recognized that we needed to go beyond the integrated injectors and closed-loop system of the shredder, so we began researching additional mitigation techniques."

"The portability appealed to us, so we could position it to accommodate different wind directions."

Part of the challenge was the size and complexity of the processing line's conveyor system, which measures 300 feet end-to-end and includes 17 conveyor segments in all. Dust could be generated from a number of feeds and transfer points and the weather was a large factor in determining where suppression was needed on any given day.

After finding an Internet video featuring the DustBoss and learning about a standing offer for risk-free rental, the company arranged an equipment trial.

"We tested a DB-60 at the stockpile where incoming material feeds onto the conveyor," the manager said. "The portability appealed to us, so we could position it to accommodate different wind directions."

Company officials were so pleased with the results that they decided to purchase the unit.

Added Control

In an effort to achieve even greater dust suppression, the customer also added water nozzles to some of the conveyors, but officials noticed that material dropping from the incoming feeder to the main conveyor continued to generate a significant amount of dust.

To address the issue, they decided to conduct a trial with a DustBoss DB-45, a mid-sized unit. Positioned over the shredder to alleviate airborne particles at the transfer point, the DB-45 helped control the dust without over-saturating the material, and company officials decided to purchase the second unit.

With the two dust suppression units in place, the manager said the facility has been able to run the shredder continuously, five days a week.

"We've been very happy with the results we've achieved," he said. "We received excellent service and support and I would recommend the DustBoss to other shredding companies."

New DustBoss units are covered by an industry-best 5-year/5,000 hour warranty.

CUSTOMER
Metal Recycling Operation

LOCATION
Midwestern U.S.

CHALLENGE
Find a way to control dust from a high-volume metal shredding operation, helping the customer obtain EPA approval to install new and larger equipment that would allow the company to increase production and compete in new markets. The solution also had to meet with the approval of a local group as an appropriate dust control plan.

SOLUTION
Two DustBoss® 60s (DB-60s) and one DustBoss 45 (DB-45)

RESULTS
The company first rented a DB-60 on a risk-free trial basis, which led to the purchase of two machines, becoming a key element in the dust management solution and helping the company secure EPA approval for a new 4,000 HP shredder. The equipment has been so effective that operators have been able to run the new shredder line even on days when unfavorable wind conditions exist, contributing to a production increase of as much as 30%.

Dust Control at Metal Recycler Shredder

One of the largest metal recyclers in the Midwest is knocking down shredder dust with a pair of dust suppression systems, helping operators to increase production by as much as 30 percent.

"We recognized that we needed to go beyond the integrated injectors and closed-loop system of the shredder, so we began researching additional mitigation techniques."

A spokesman said the equipment is so effective that the company can now run its shredder line even on days when dusty source materials and unfavorable wind conditions might have prevented operations in the past.

The powerful DustBoss dust suppression machines were also a key element in securing EPA approval for a new shredder. Successfully meeting the requirements allowed the facility to begin processing automotive scrap, a market in which it could not be competitive using its existing equipment.

In addition to aiding the permit process, the company estimates the benefits have been so significant that the dust suppression system paid for itself in about six months.

The scrapyard dust control plan

The recycling facility is a privately owned scrap buyer and recycler processing about 30,000 tons per month of both ferrous and non-ferrous scrap.

The firm recycles aluminum, stainless steel, copper, brass, allows and all grades of iron and steel. The company accepts aluminum cans, appliances, radiators, junk cars, trucks, construction steel and siding from businesses and consumers.

About 1,500 tons per month is municipal debris (incinerator scrap), which has a high ash content and large potential for dust generation.

In late 2008, company officials wanted to gain process efficiency and broaden recycling capability by installing an American Pulverizer 80x104, a 4,000 HP machine capable of shredding 100+ tons of metal per hour. The unit features water injectors to control dust and prevent explosion hazards, as well as a closed-loop conveyor system to mitigate dust when materials go through the separator.

Dust Suppression at Metal Recycler

In addition to greater shredding ability, the AP design would allow the firm to eliminate shearing and baling of materials that could not be shredded with its existing production line.

"To obtain EPA approval to install the new equipment, we had to satisfy specific requirements during the permit application process. We also worked with a local group to develop a dust control plan," said the Shredder Operations Manager. "We recognized that we needed to go beyond the integrated injectors and closed-loop system of the shredder, so we began researching additional mitigation techniques."

"The portability appealed to us, so we could position it to accommodate different wind directions."

Part of the challenge was the size and complexity of the processing line's conveyor system, which measures 300 feet end-to-end and includes 17 conveyor segments in all. Dust could be generated from a number of feeds and transfer points and the weather was a large factor in determining where suppression was needed on any given day.

After finding an Internet video featuring the DustBoss and learning about a standing offer for risk-free rental, the company arranged an equipment trial.

"We tested a DB-60 at the stockpile where incoming material feeds onto the conveyor," the manager said. "The portability appealed to us, so we could position it to accommodate different wind directions."

Company officials were so pleased with the results that they decided to purchase the unit.

Added Control

In an effort to achieve even greater dust suppression, the customer also added water nozzles to some of the conveyors, but officials noticed that material dropping from the incoming feeder to the main conveyor continued to generate a significant amount of dust.

To address the issue, they decided to conduct a trial with a DustBoss DB-45, a mid-sized unit. Positioned over the shredder to alleviate airborne particles at the transfer point, the DB-45 helped control the dust without over-saturating the material, and company officials decided to purchase the second unit.

With the two dust suppression units in place, the manager said the facility has been able to run the shredder continuously, five days a week.

"We've been very happy with the results we've achieved," he said. "We received excellent service and support and I would recommend the DustBoss to other shredding companies."

New DustBoss units are covered by an industry-best 5-year/5,000 hour warranty.

Implement Dust Control at Your Jobsite!

Receive a FREE quote and talk to a dust control specialist today to stop fugitive dust!

Get A Quote

More on BossTek

Using DustBoss Cannons for Dispersing Disinfectant

By BossTek | March 27, 2020

Across the world, officials are looking for ways to combat the spread of disease. Many countries are turning to water cannons and misting systems to distribute disinfectant on a larger scale. Doing so can facilitate cleaner environments, both indoors and outside, while minimizing the number of personnel required for such cleaning processes. For decades, DustBoss®… Continue Reading

Urban Demolition Project Uses Atomized Mist to Comply with Dust Regulations

By BossTek | March 18, 2020

A Colorado demolition firm with a reputation for environmental stewardship on complex large-scale projects has successfully complied with strict urban dust suppression regulations throughout a sensitive 18-month demolition project, from structural implosion to site clearing.  Using two atomized misting cannons to control dust created by the takedown, Colorado Cleanup Corporation (CCC) was able to demolish… Continue Reading

Aluminum Die Caster Uses Air Cannons For Positive Airflow & Temperature Control

By BossTek | March 4, 2020

A pioneer in dust and odor control equipment has helped an aluminum die casting company cool its operations and create a more pleasant working environment by employing powerful air cannon technology. LeClaire Manufacturing is using two DustBoss® DB-30™ dust cannons from BossTek® to improve airflow, reduce indoor temperatures and direct air toward internal ventilation systems. … Continue Reading

Industrial Dust Collector – Dust Control Method

By BossTek | February 19, 2020

Past large misting cannons and nozzle-based fogging systems, industrial dust collectors are a large source for dust control. Their applications vary from the two water-based systems and provide optimal dust suppression in operations where water is not wanted. Learn more about how all three of the systems are effective solutions to remove dust from the… Continue Reading

Demolition Contractor Controls Dust Levels in Highly Regulated Hospital Zone

By BossTek | February 5, 2020

The Medical University of South Carolina (MUSC) in Charleston is one of the state’s top hospitals, ranked among the best pediatric medical institutions in the country.  The facility is in the process of expanding and upgrading — supported by donations, grants and state contributions — and has begun construction of the MUSC Shawn Jenkins Children’s… Continue Reading

Remove Dust from the Air at Industrial Sites

By BossTek | January 22, 2020

Trying to stop dust from getting in the air is a valiant effort. Unfortunately, it’s a hard fought battle. In most scenarios, dust is going to be generated and released into the air upon disruption. The demolition industry has copious amounts of dust created during the tear down of structures that preventive methods are not… Continue Reading

Subscribe and Stay Up-to-Date!

Receive a monthly newsletter keeping you up-to-date on the latest in dust and odor control.

Subscribe

This entry was posted in Blog Separation, Bulk Material Handling, Case Study, Case Study Blog, DB-45, DB-60, DB-60, Dust Control, Dust Control, DustBoss, DustBoss, News, Recycling / Scrap, Rentals, Scrap Metal Recycling, Shredder, Standard, Stockpile. Bookmark the permalink. Both comments and trackbacks are currently closed.