At Spray Nozzle Engineering, we understand that mining and quarrying operations face a constant battle against airborne dust. Not only does excessive dust reduce visibility and create an unsafe working environment, but it also poses significant environmental and health risks. Recently, a large quarry reached out to us desperate for a more effective dust‐suppression system. What they described was all too familiar: during rock crushing and conveyor transport, dust clouds billowed over their site, creating compliance headaches and increasing the risk of respiratory issues for their workforce.
The Challenge: Ineffective Dust Control with Dribble Bars
This quarry had initially tried a seemingly straightforward approach: dribble bars mounted along the conveyor. The concept is simple—allow water to “dribble” onto the belt so that when the rocks pass beneath, the moisture binds dust particles and prevents them from becoming airborne. In practice, however, dribble bars often fall short for three key reasons:
-
Poor Atomization
Dribble bars deliver large droplets that simply do not break up fine dust particles. These droplets tend to roll off rocks instead of clinging to the dust itself. -
Uneven Coverage
Conveyor belts are wide and irregular in rock profile; dribble bars cannot guarantee uniform water coverage, leading to dry spots where dust still escapes. -
Excess Moisture
When conveyor speeds vary or flux of material is high, dribble bars can over–wet the product—something this quarry could not tolerate, as excessive moisture impacts downstream processing and product quality.
After months of sub‑par performance and ongoing maintenance headaches, the quarry recognized that dribble bars alone were insufficient. They needed a solution that delivered consistent, fine mist across the entire belt without saturating the rock.
The Solution: BETE P‑Series and TF‑Series Nozzles
Enter the BETE P and TF nozzles—precision‐engineered atomizing nozzles known for their ability to create ultra‑fine mists. Our team recommended a staged installation:
-
P‑Series Misting Nozzles
These nozzles produce a dense, misty spray pattern. The cone intercepts either the falling material or material on the conveyor, enveloping it in a fine mist that captures dust at its source. -
TF Spiral Nozzles
Positioned either along conveyor transfer points or when falling, TF nozzles generate a uniform, full‐pattern flat spray. This pattern covers the entire belt width with micron‑sized droplets that bind to dust particles without creating puddles or runoff.
By combining the two types of nozzles, we created an overlapping matrix of atomization zones—maximizing dust capture while minimizing water usage.
Why Finely Atomized Mist Matters
The key to effective dust suppression is droplet size. Large droplets behave like raindrops—hitting the rock, splashing, and running off, with minimal dust capture. In contrast, droplets in the 50–100 micron range act like snowflakes: they drift and gently collide with fine dust particles, adhering to them and causing them to settle. This “fog‐like” mist:
-
Minimizes Water Consumption
Micro‐droplets use less water per unit of dust captured compared to conventional sprays. -
Prevents Over‑Wetting
Because each droplet is so small, there’s virtually no pooling or runoff. Rocks remain dry enough for processing. -
Improves Worker Safety
Visibility is restored, and airborne silica dust concentrations are drastically reduced—protecting employee health and helping the site maintain regulatory compliance.
Why Choose Spray Nozzle Engineering?
At Spray Nozzle Engineering, we pair world‑class nozzle technology like BETE’s P and TF series with hands‑on application expertise. From initial site surveys to final commissioning and ongoing support, we ensure your dust‐suppression system delivers peak performance:
-
Custom System Design tailored to your throughput, environment, and budget
-
Comprehensive Testing to validate droplet size, coverage, and efficacy
-
Turnkey Installation—we handle piping, fittings, controls, and calibration
-
Maintenance Training so your team can keep the system running smoothly
Dust control is more than a compliance checkbox—it’s a critical investment in your operation’s safety, efficiency, and sustainability. If you’re struggling with airborne dust at conveyors, crushers, screens, or transfer points, let our experts design the right solution using BETE’s precision nozzles.
