CA1114281A - Suppression of respirable dust - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

This invention suppresses dust, and particularly respirable dust, by preventing the dust from becoming airborne at locations where it could escape from the dusty material with which it is associated, for example, at transfer points and other locations where the respirable dust can be released into the surrounding atmosphere. Foam, having bubbles small enough to be broken by respirable dust particles, is brought in con-tact with the respirable dust where small bubbles, small enough to be bursted by respirable dust particles, are imploded and the bubbles wet the dust particles and cause adherence of the particles to adjacent surfaces, such as other foam or other parts of the dusty material. The foam may be discharged into dusty material at transfer points where the dusty material falls by gravity and thereby opens up spaces between portions of the material which are at zero gravity as a result of their free fall.

Description

BACKGROUND AND SUMM~P~Y OF THE INVENTION
The term "foam", as used herein, designates a mixture 20 of liquid, gas, and a surfactant that gives the liquid a film strength which permits the formation of long lasting bubbles when the mixturb is agitated to convert it into a mass of bubbles. The liquid used is normally water, and the gas is usually air, because these ingredients are of low cost; but bther gas and/or liquid can be used when compatible with the surfactant.

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Various compounds are used as surfactants, and these can be purchased on the open market. Some of these compounds are proprietary. The strength of the film depends upon the characteristics of the surfactant, and the amount of the sur-factant in the liquid-gas mixture, as will be more fully explained.
In order to have small particulate matter efficiently trapped, it is necessary for the particle to contact with a bubble of the foam and burst the bubble. As the bubble bursts, the gas in the bubble escapes; the bubble implodes; and the liquid film of which the bubble was made coats the particle~
Small particles do not burst large bubbles and are not wetted or trapped by the foam. The smaller the bubble, the smaller the particles that can be trapped. This invention traps all detectable particles as a result of smaller bubbles made with higher strength foam.
The foam described in this specification has the bubbles burst by contact with small particles of material (dust) and the bursting bubble wets the particle. Particles as small as one micron are readily wetted. As this effect proceeds, the foam is destroyed by contact with the particles. The wetted particles must then be either 1) brought together,

2) made to contact larger particles, or

3) brought into contact with a surface, which may be additional foam.
If the foam is injected into a free-falling aggregate (at a transfer point between belts, for example, or injected into a crusher along with the aggregate), the mechanical motion of the aggregate will provide the required particle-to-particle contact. When the foam is injected into an aggregate which is ' .. ..

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all fines (one to two hundred micron), some means must be pro vided to cause the wetted particles to coalesce. This is readily accomplished by use oE a cyclone.
Another advantage of small bubb:Le foam is that it can be ejected from noz~les at considerable pressure and resulting high velocity. This will be explained more fully in the des-cription of the preferred embodiment.
Other objects, features and advantages of the inven-tion will appear or be pointed out as the description proceeds.
BRIEF DESCRIPTION OF_DRAWING
In the drawing, forming a part hereof, in which like reference characters indicate corresponding parts in all the views:
Fig. 1 is a diagrammatic sectional view showing a foam generator for making small bubble foam which is used with this invention;
Fig. 2 is a diagrammatic view showing a cyclone sepa-~; rator equipped with a foam supply and with means for withdrawing . :-particulate matter from the cyclone chamber in a foam slurry;

Eig. 3 is a sectional view taken on the line 3-3 of Fig. 2; and Fig. 4 is a diagrammatic view of a transfer point for dust-laden material with foam projected into the transferring ;' ' material.
, DESCRIPTION OF PREFERRED EMBODIMENT
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The mixture used for this invention is preferably a mixture of airt water and a surfactant that is made for "high ' expansion foam " Such a foam has a high expansion ratio when '~ the foam is developed by conventional fire equipment; that is, ; 30 an ultimate vo:Lume of foam which is from 100 to 1000 times, or more, of the volume of the water and surfactant from the foam is formed.

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While the present invention uses a surfactant of this type in order to obtain great film strength/ the expansion ratio is reduced by the fact that the foam is made with small bubbles.
Bubble formation in making foam with my equipment is -the result of vortex effect in a passage. The boundary layer of the un-foamed mixture drags on the sides of the passage, and the smaller the passage, the more the turbulence and vortex action.
Fig. 1 is a diagrammatic sectional view of apparatus for making the small bubble foam of this invention. The mixture of water, air and surfactant ("foaming agent") is forced by the pump 10 into a foamer 12 which contains a cartridge pad 14.
This pad 14 has a myriad of small interconnecting interstices. It may be a sponge made of polyurethane or other plastic; but the preferred structure is a stainless steel .- :~
;~ scouring pad sold under the trademark "CHORE BOY" and manufac-tured by Metal Textile Co., P.O. Box 315, South Bound Brook, New Jersey, 08880.

One or more of these pads 14 are stuffed into the `:~
~ hollow interior of the container 12 until the full cross-section ~ ,. ..
~; 20 of the container is evenly filled across one end of the interior of the container, as shown ln Fig. l. ~ perforated partition 16 in the container is positioned to divide the container into a pad chamber 18 and a foam chamber 20. The small bubble size is obtained by pushing the unfoamed mixture through a myriad of tortuous passages under sufficient pressure to obtain a high velocity that will result in the small foam bubbles.

With the CHORE BOY scouring pad 14 stuffed into the chamber 18 of the container 12, with a diameter "D" of three inches, and with the scouring pad of an axial length of approxi-; 30 mately three inches, the foam should be discharged from an outlet 22 at the rate of from five to ten cubic feet per minute in order ~a_S_ , -: , . . . . . .
- .;, to have the necessary velocity through the foaming pad 14 to produce the small bubbles required by this inven-tion. This example is given merely by way of illustration. The mixture supplied to the foamer 12 has water equal to from 1 to 4% of the volume of the air and the surfactant is from 1 to 6% of the volume of the water and preferably 2%. The expansion ratio of the foam may be from 25 to 100.
Expansion Ratio =

Vol. gas Vol. liquid Suitable surfactants can be purchased from suppliers of fire-fighting foam as listed in the yellow pages of the `~ telephone directory of any city of moderate size. It can also be obtained from the DeTer Company, Inc., of Mountain Lakes, New Jersey.
Conventional foams can flow by gravity and can be pushed through passages if the pressure is low. High velocity foam has to have considerable pressure behind it, and this is possible with foam having very small bubbles but cannot be used for large bubble foam because the bubbles collapse. Thus small ; bubble foam can be penetrated into a dusty mass of material such as at material transfer points already described. The equipment shown in Fig. 1 will produce foam having bubbles between .0005 and .015 inch. This will trap particulate matter as small as 1 micron in diameter and carry large pieces up to 1 inch in size. The foam can effectively trap such small par-ticles if the average size of the foam bubbles in less than .015 inch; but the same amount of foam will trap more particles if all of the bubbles are smaller than .015 inch and preferably between .0005 and .015 inch, as already described.

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The outlet 22 of the foamer 12 has a flexible pipe or hose 24 leading to a nozzle 26 from which foam 27 is discharged under substantial velocity -for permeation through a mass of dusty material at a transfer point or other location where the material is in motion, and dust would be clischarged into the ambient atmosphere if the foam 27 were not used to suppress the dust.
Fig. 2 of the drawing shows a cyclone separator 30 which has a frusto-conical separation chamber 32 with a wall 34 that extends downward to an opening 36.
Gas, laden with particulate matter, flows into the chamber 32 from a passage 40 at the upper end of the chamber 32.
This passage 40 is positioned to discharge its gas stream tangentially around the circumference of the upper part of the chamber 32 and in contact with the wall 34.
The passage 40 discharges gas into the separation chamber, which has a cover 35 and the gas flows downwardly with a swirling movement and increasing veIocity as the cross-section of the separation chamber decreases. Particulate matter in the gas is thrown outward by centrifugal force~ and the gas, separated from its particulate matter, reverses its ~low at the center xegion of the separation chamber and flows upward to an outlet discharge 44 which extends upward through the top of the chamber and in substantial alignment with the axis of the chamber 32. The construction and operation of the cyclone separator, thus far described, is in accordance with conventional practice.
This invention introduces foam into the particulate laden gas stream. In the illustrated embodiment, the foam is injected into the gas stream by a nozzle 46 which extends into the gas inlet passage 40 upstream from the outlet of this passage 40 where the gas flows into the separa-tion chamber 32. The foam traps the particulate matter and forms, with the particu-late matter, a slurry.
The coating of slurry, indicated by the reference character 48, on the wall of the separation chamber is indicated in elevation by stippling in the drawing and is shown in section where the wall 34 is shown in section. The slurry 48 runs down the wall and accumulates in the lower part of the separa-. tion chamber 32 at the opening 36 which is normally closed by a bottom 50.

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: -8-In the construction illustrated, the bottom 50 is supported from the wall 34 b~ a bracket 52 to whlch the bottom is connectea by a hinge comprising a pin 5~ which extends "' . through one side of the ~ottom 50 and through aligned openings ' 5 in the brac~et 52. A spring 56 is connec~ed at one en~ to the bracket 52,.and the other end of the spring 56 contacts ith the bottom 50 to hold the bottom in a position to close the opening 36, as indicated in full lines in Fig.2. ~en sufficient weight of slurry accumulates in the lower end of . 10 the separation chamber 32, the weight of the slurry overcomes the force of the spring 56 and causes the bottom ~0 to swing . into an open position, as indicated in dotted lines in Fig. 2.
The accumulated slurry arops out of the chamber, and the spring 56 pushes the bottom ~0 back into closed position.
`~ 15 . A foam generator 60 supplies the nozzle ~6. Foam generators are well-known, and the block'diagram of Fig. 2 '. is sufficient for a complete understanding of this invention.
Water, air and foaming.agent are supplied to the foamer 60 from a mixer 62; and the water, air and foaming agent are : 20 ' supplied to the mixer 62 through pipes 6a, 65 and 66, re-spectively.
Each of the pipes 64, 65 and 66 is shown with a vàlve 68 for regulating the supply of water, air or foaming agent, and the proportions in which these ingredients are : ~5 supplied to the mixer 62. These'valves 68 are merely repre-: sentative of means for controlling the supply of the ingre-dients to the mixer 62 and for proportioning the in'gredients.

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~lore elaborate c:orlL;.rols for t'ae inclr~di.ents supplied to the mixers 6~ can be us~d, such as flui.d flo,~
regulators that receive flui.d a-t variable pressu,e and ,~ deliver it at a uniform pressure and/or ~lo~, These controls are adjustable to re~ula-t:e the proporti.ons supplied to a mixer. Such controls are also well-known,and the particular . apparatus used for controlling the flow and proportions of the ingredients is a mat-ter of choice ~ Experie*ce has shown that it is not essential to 10 supply foam continuously to the separator. It is sufficien-t '~ that -the ~all of the separation chamher be at least par-tially coated with foam at all times. In order to conserve foam, a control valve 70 is located between the mixer and the ~oamer-for shu-t-ting oEf the mixture at times when no foam is required . In order to program the supply of foam with the operatlon of the cyclone separator of a cycle -timer 72 controls . a power supply to a solenoid or other actua~,or'7~ for the ' valve 70. The cycle timer 72 opens.and closes the valve 70 C 20 periodically and for such leng-th of time as necessary to maintain the re~uired amoun-t of foam in the separation chamber.
' . . In accordance with conventional practice, the gas ~ .
- and particulate matter is supplied to -the separator by a ' cen-trifugal blower 76 or other apparatus for moving the air and solids.

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Fig. 4 sho.~7s a bel-t conve~or 80 which -transfers coal 82, or other dusty ~aterial, to truc~; 86. As the coal falls into the truck 86, dust ~70uld float off into the ambient atmosphere; and khe smaller par-ticles are the most objectionable because they are lighter and remain airborne for larger periods of time.
Foam nozzles discharge small hubble foam 90 into the moving mass oE coal, and the foam contacts 7ith the dust present in the fàlling coal. The dust particles burst the bubbles with which they contact, and the implosion of the bursting bubble traps and coats the dus-t particles with the liquid o which the bubble was formed.
This traps the wetted particles on the surEace of adjacent material~ With broken dusty material, the dust is suppressed by projecting the small bubble foam into the broken material while said material is in mo-tion.
Where the transfer of dusty material fxom one suppor~ to another is by free fall to the other suppor-t, the small bubble foam is projected into the material to trap the dust thereof while larger particles of the material are separated from one another as a result of the free fall.
The preferred embodiment of this invention has been illustrated and described, but changes and modifica,ions can be made, and some features can be used in different 2~ combina-tions without departing from the invention as de-fined in the claims.
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Claims (7)

WHAT IS CLAIMED IS:

1. Apparatus for preventing respirable dust particles from becoming airborne in coal mines and at other locations where respirable dust particles may escape from broken dusty material in motion comprising means for supplying foam to the dusty material including in combmation a foamer, means for forcing a mixutre of air, water and surfactant through the foamer, under high pressure and at high velocity to form a foam in which bubbles discharged from the foamer are small and of a size of .015 inch and smaller, means for moving the material and causing relative motion of the respirable dust and other pieces of the material, means for discharging the foam into contact with the moving ma-terial and into any clearance between pieces of said material, so that any respirable dust in the material that might otherwise escape from said broken material and become airborne, while the material is moving, contacts with and implodes a small bubble and become wetted thereby, and the capacity of the means for supplying the foam to the dusty material being correlated with the means for moving the material to supply foam in sufficient quantity to maintain small bubbles of the foam at locations where respirable dust could otherwise escape from the dusty material and into the atmosphers, whereby the particles of respirable dust contact with the outsides of said small bubbles and are wetted and adhered to adjacent material.

2. The apparatus described in claim 1 characterized by the means for moving the material including a part where the material is in a mass, that the foam cannot penetrate, and in-cluding also a support to which the moving material is de-livered at a lower level than said part so that the material separates as a result of the acceleration of gravity as the material falls to said lower support, the acceleration of gravity causing separation of pieces of the material and open-ing up of the clearances between pieces to expose the dust in the clearances to the foam.

3. The apparatus described in claim 2 characterized by the means for moving the material being a conveyor from the end of which the dusty material drops to said support, said support being at a lower level than the conveyor, and foam discharge nozzles in position to discharge foam at locations where the clearances are opened up by the dropping of the dusty material from the conveyor.

4. The apparatus described in claim 3 characterized by the conveyor being at a higher level and clear of the material on the support to provide free fall of the dusty material from the conveyor to the support, and foam nozzles at different loca-tions around the falling material where the free fall leaves the material and dust at zero gravity during the fall where respirable dust would float. from the falling mass into the sur-rounding atmosphere, the foam being discharged into the falling mass so as to fully penetrate clearances in the mass and prevent respirable dust in the material from becoming airborne.

5. The apparatus described in claim 2 characterized by the conveyor being a coal mine conveyor that carries lumps of coal and dust including respirable dust along with and on the lumps of coal, the means for supplying the foam being a plural-ity of nozzles that discharge the foam into clearance between the falling lumps from different sides thereof, the foamer and nozzles being of sufficient capacity to supply sufficient total foam to the broken dusty material to leave some foam on the mass of material when said material reaches the support.

6. The method of preventing respirable dust from becoming airborne, which method comprises:
a) forcing a mixture of air, water and surfactant through a foamer having tortuous passages and under high pres-sure and high velocity to form a foam in which bubbles dis-charged from the foamer are small and of a size of .015 inch and smaller;
b) bringing the foam promptly, while most of the small-bubbles persist as such, into contact with dusty material containing respirable size dust particles within the size range of 1 to 200 microns;
c) causing relative movement of the foam and dusty material and by such relative movement causing the respirable dust particles and small bubbles to contact one another at a location at which the small bubbles persist;
d) wetting the respirable dust particles at said location by implosion of the small bubbles with which said respirable dust particles come in contact;
e) supplying enough of said small bubble foam to wet substantially all, or any selected portion of, the re-spirable dust; and f) providing material at said location adjacent to the implosion of the small bubbles by the respirable dust par-ticles and to which adjacent material the wetted respirable dust particles attach themselves.

7. The method of suppressing respirable dust as described in claim 6 characterized by advancing the material with which the foam has been brought in contact, and bringing other dusty material into position for contact with additional foam containing the small bubbles at said location.