Effective dust control and spillage management are critical in conveyor systems for maintaining operational efficiency, safety, and compliance with environmental regulations. Here are the primary strategies, solutions, and best practices used in modern conveyor operations:
Dust control methods
- Water sprays and fogging: applying water sprays along the conveyor and especially at transfer and drop points suppresses airborne dust by binding fine particles and preventing them from escaping into the air. Automated fogging systems at transfer points are highly effective in capturing dust as material moves from one conveyor to another.
- Enclosures and covers: enclosing the conveyor belt, either fully or at key points such as transfer stations, minimizes wind currents and contains dust within the system, allowing particles to settle rather than escape.
- Skirting and sealing systems: specialized skirting and sealing solutions are installed at loading and transfer points, creating a tight seal between the conveyor belt and the stationary structure, stopping dust from leaking out. Dual or self-adjusting skirting, as well as contact-free or wear-resistant polyurethane skirting, greatly reduce dust emissions and the need for maintenance.
- Engineered transfer chutes: chutes designed to reduce drop height and control material flow minimize abrasive impacts and dust creation. Controlled trajectory loading and “hood and spoon” designs improve dust control by reducing air velocity.
- Passive barriers and curtains: dust curtains and stilling zones slow down air movement, giving particles time to settle and preventing them from being carried out of the system.
- Dust collection systems: where suppression and containment measures are insufficient, mechanical dust collectors or filtration units can capture residual airborne dust for safe disposal.
- Belt wipe systems: continuous belt-cleaning devices remove fine particles (fugitive dust) from the belt, returning them to the main material stream and reducing the risk of dust clouds.
Spillage management techniques
- Loading zone containment: the key area for spillage is at conveyor loading zones. Troughed belts, proper skirtboards, tight-sealing aprons, and impact beds help contain material and absorb the shock of loading.
- Belt alignment and tracking: misalignment can cause the belt to wander and spill material. Regularly check and maintain idlers and pulleys to keep the belt centered. Installation of belt tracking or training devices is recommended for persistent issues.
- Slider beds and reduced idler spacing: at critical points, replacing idlers with slider beds and decreasing idler spacing at load zones eliminates belt sag, closing escape routes for material and improving the seal with skirting systems.
- Carryback management: install secondary belt cleaners to remove fines and sticky material from the return side of belts, reducing the risk of material dropping off and accumulating, which causes more spillage down the line.
- Regular maintenance: consistent inspection and timely replacement of worn skirting, seals, and belt-cleaning devices help prevent recurring dust and spillage problems.
A combination of engineering controls (enclosures, transfer chute design), high-quality skirting, regular maintenance, and where necessary, active suppression or collection systems, provides comprehensive dust and spillage management. Newer contact-free and automated solutions further reduce maintenance and operational costs while improving overall performance.
