To atomize a substance is to convert it into very fine particles or droplets.
Atomized mist technology uses special atomizing nozzles to fracture the stream into millions of fine droplets of water. Different nozzles, as well as different engineering, can produce differently sized droplets.
Atomized mist has many applications. The DustBoss, for example, has been used to cool concert goers and maintain the proper humidity for curing concrete.
However, the DustBoss is specifically designed for dust control, as the OdorBoss is for odor control. Both operate under the same logic, which is to match water droplet size with that of its target.
If the water droplet is larger than the dust particle, the dust particle has a tendency to follow the airstream around the drop. If the diameters of the droplet and particle are comparable, the droplet is more likely to collide with the dust, driving it to the ground.
Chasing odor producing molecules demands the same considerations, often necessitating significantly smaller water droplets than what is needed for fugitive dust.
The other reason this technology works so well is because it uses significantly less water than traditional methods such as firehoses and sprinkler systems, which use 20 times more water than atomized mist. The original intention of those products is to provide the heavy water flow that is unnecessary for dust control.
Dust suppression refers to any dust control that uses water. Water often plays a prominent role in a fugitive dust plan because it is usually cheap, easy to obtain, and safe for the environment (except in times of drought).
Under the category of dust suppression, there are two types: surface and airborne.
The idea behind surface suppression is to inundate the material with water, increasing dust particle size and weight in order to keep dust from taking to the air. Not only does water make dust heavier, it increases cohesion, making the particles more likely to agglomerate into heavier particle groupings. Industrial sprinklers and hoses accomplish that task, even if they use more water than necessary.
Technology such as fog cannons create small enough particles to be effective against airborne dust, but lack the moisture to seal the surface to prevent more dust.
Atomized mist achieves small enough droplets to capture dust in the air, but also provides enough moisture to wet the surface like sprinklers and hoses do. Atomized mist is the only current technology that provides both airborne and surface dust suppression.
Mist cannons use a powerful ducted fan to propel tiny water droplets up to the distance of an American football field.
To say the fan is ducted means it is encased in a cylindrical barrel. Think of a jet propeller. Ducted fans on our units range from 7.5HP to 60HP powering anywhere from a 9,000 to 40,000 CFM fan, depending on the coverage needed.
Our fans are powered by electric motor. We have found electric motors are less maintenance and lasts longer than any other motor options.
Sometimes there are situations where aggressive coverage is not necessary or a ducted fan would create too much disturbance.
Atomized mist can be applied through spray bars or other misters, such as our DB-M and DB-M Mini, which including misting heads on booms. DB-M Minis are often used on crushers or for indoor applications and are powered only by the water running through them.
Spray bars can be custom built to fit almost any application. A common need is for rings that fit around conveyor discharge, creating a curtain of mist around the falling material.
DustBoss customers have seen some success metering in odor control chemical to the stream using a dosing pump, adding a dual purpose to the dust suppression machine. However, the water flow and droplet size of the DustBoss is built for dust and cannot realize the results we know are possible.
Our line of OdorBoss units deploy two methods of attack: air and surface.
The OdorBoss Gaseous (OB-G) is engineered specifically to disperse air treatment chemical, using water as the delivery vehicle. The fan generates wind movement, propelling the treatment into the air where the chemical converts into a gas and attaches to odor producing molecules.
The OdorBoss Topical (OB-T) with surface treatment deodorizers is designed to attack odor at the source. The OB-T can be fed from a hose with a dosing pump cycling through the deodorizer. Alternatively, it can be paired with a water tank for premixing, both of which are placed on a trailer for mobility.
Topical treatment deodorizers are designed to land on odor producing surfaces, nullifying the odor before it becomes airborne. This method is extremely effective, but not always economically feasible for larger coverage areas or when the material is disturbed often.
The longevity and low maintenance of a DustBoss can be largely credited to its “complex in its simplicity” direct-drive design. While a DustBoss does not need to be greased every day, it does require a nearby power source.
The DustBoss Fusion pairs a DustBoss with a generator and places the package on a trailer for easy mobility.
DustBoss units can be equipped with an optional dosing pump to meter in various chemicals for dispersal.
- Tackifiers help seal stockpiles, providing further defense against the wind. Tackifiers increase tack, or stickiness of the surface.
- Surfactants lower the surface tension of water droplets, making it easier for the droplet to collide with airborne dust particle. Surfactants are particularly helpful with more hydrophobic materials such as coal.
- Odor control deodorizers work by attaching to odor producing molecules and using active chemistry to change odorous elements into something else through chemical change. The OdorBoss deodorizers work best with the OdorBoss, but a DustBoss can achieve some success if dual purpose is required.
Contact us for more information regarding our chemical solutions.
One thing that sets DustBoss apart is the potential for customization. Whether it is a custom-shaped spray bar, freeze protection, or new remote capabilities, DustBoss technicians and engineers have accepted many challenges over the years and the technology continues to develop with each customer request.
Every site is different. While the DustBoss can be a plug-and-play system if that is what is required, there are endless opportunities to make this dust suppression system a perfect fit for your facility and processes.
DustBoss can be specified with any number of mounts for different situations, including:
- 3-Wheeled Carriage: For greater mobility
- Skid: For bolting in spot and transfer with forklift
- Tower: For fixed location needs, elevating the DustBoss increases effectiveness
DustBoss units have been configured to suppress dust in many different settings, including mounted to ceilings. Talk to us about your unique situation and we can recommend a mount.
All individual functions of the DustBoss and OdorBoss fan units can be control by remotes from about a thousand feet away. We offer various degrees of control based on your needs and budget.
The machine can be programmed to run a certain way. For example, it can be set for the duration of run, programmed for intervals of inactivity.
Units can even be equipped with weather stations, enabling them to turn on and off based on wind direction and humidity.
Automation and remote technology becomes more dynamic as customer requests for new functions. Let us know what you want your equipment to do and we will accept the challenge.
While potable water works best, dirty water can be used with the proper filters. We have customers who pull the water straight from the Mississippi River.
It is important to clean the nozzles when necessary. Dirtier water plugs nozzles more often, which is hard on the pumps.
Our more powerful units use a 1 ½ inch (38.10mm) fire hose, which connect to a cam-and-groove quick disconnect female coupling on the machine. The DB-30 and DB-M Mini use 5/8 inch (15.8 mm) garden hoses. Request spec sheets of the individual products for more details.
Refer to the spec sheets of the individual products for electrical recommendations.
Our direct drive dust suppression fan units require minimal maintenance. The fan motor and high pressure pump should be greased every 10,000 hours. Turntable bearing should be greased on a regular maintenance schedule, or as needed.
If using potable water, nozzles need to be inspected once a year. You will have to clean the nozzles more often when using dirtier water.
Quick release brackets are available for the manifolds in order to reduce the amount of time that the DustBoss has to be turned off for maintenance. These brackets allow the user to quickly swap the spray manifold and then to clean/replace nozzles on the dirty manifold at their leisure.
DustBoss units do not make snow in freezing temperatures and can be run successfully with some preparations.
Components of the machine can be heat traced and valves can be strategically placed to avoid freezing water lines.
Workers will need to be mindful of ice that may form under the plume where water is falling to the ground and freezing.
Renting and Purchasing
Yes. You can rent a mist cannon to decide if it will work for your situation. The first month’s paid rent can be applied to the purchase.
If you decide after one week that the equipment is not doing what you need it to do, we’ll pick it up and you will only be responsible for freight.
For our equipment, we offer a three year or 3,000 hour warranty. Generators are warrantied for two years or 2,000 hours.
There are several things that need to be considered, including coverage area, volume of dust being produced, placement restraints, and wind. It is best to contact a sales specialist who can review your site and determine the minimum that is required.
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Every site is different. Let us find the right solution for you.