DUST ELIMINATION MECHANISM (WET SCRUBBER)

By

KUBVORUNO PRIDE TAFADZWA

OF

MIDLANDS STATE UNIVERSITY

FOR

BULAWAYO MINING COMPANY

EXECUTIVE SUMMARY

Noticing the need for a creation of best working condition at 28 level, the thought of doing a project
which will help create a best possible working condition hit the proposer. The proposer together with
his team mates will design a system which will suppress dust by sucking it from the ore pass and
capture it by the use of fine water sprays in a cyclone. The design of the system is drawn to scale,
mathematical calculations done on how it will operate. The teams members will each have a role to
play doing tasks as per assigned until the systems is done and running as per expected
Problem Statement

Bulawayo mining company (BMC) is a mining company which is in a business of mining gold. It is an
underground mine using sub-level open stope as a mining methods. It is comprised of sublevels and
main haulage levels which are used as production levels (tramming of ore). Currently 26 and 28
levels are being used as production levels. There is an ore pass from 26 to 28 level passing through
28 level. At 28 level there is a grizzly also used to tip ore into that same ore pass from 26 level. This
ore pass is also used to downcast some fresh air from 26 level to 28 . When tipping of ore is done
at 26 level, the ore face some attrition with the side walls of the ore pass as it go to 28 level,
thereby dust results from the attrition. An exhaust fan was installed facing the grizzly at 28 level to
suck the dust where by its efficiency is not seen as it exhaust the dust after it had already attacked
those working at grizzly and still the dust levels are more than the maximum required standards.

Unfortunately the dust created then becomes part of the down-casted air and is distributed into 28
level through the grizzly openings and affects those working at the grizzly at 28 level. Dust levels are
more than the maximum required by How mine standards in conjunction with OHSAS 18001.

Justification

- Bulawayo Mining Company has its own standards which they set extracting from the OHSAS
18001 and they should abide to that all the times.
- Project also needs to reduce workplace hazards and boost employee morale.
- To achieve the best possible working conditions at 28 level grizzly.
- The project will strive to eliminate dust from the source with the use the wet scrubber
mechanism.

Objectives

- At the end of the project there is hope of dust being completely exhausted direct from the
source into the wet scrubber mechanism and dealt with to an extent that we have new fresh
air to again ventilate the working place of 26 level.
- The dust suppression mechanism will comprise of;
name size Work description
1 fan 27kw Exhaust foul air (dust)
2 ducts 22 inch Direct exhausted air to wanted
destinations
3 cyclone Create votex where separation of
dust and air occurs
4 Mist eliminator Remove mist from air
5 Water pipes with To produce fine water sprays which
nozzle will capture dust in cyclone.
6 Ventilation As per To test the air output to see if it
instruments standard qualifies to ventilate other working
areas.
- The design will have an exhaust fan which will suck foul air from the ore pass and create a
negative pressure system to give room for the 28 level grizzly to down cast some air. The
foul air exhausted is entered into a cyclone where fine sprays of water are introduced to it to
capture al dust particles and to dissolve some gasses present. The captured dust particles
will come as underflow as the air will continue as overflow but now with mist in it. A mist
 eliminator will then do the magic to produce a clear air which will be tested for gasses and
dust before used for ventilating working areas.

Methodology

Steps in the design process

1. Recognizing the need; listening to the workers needs and say about the dust at 28 level.
Noting down of the dissatisfaction with the existing situation. Planning for needs to
accomplish new functionality at workplace. The projects purpose is to give workers a non-
complaining attitude towards working at 28 level grizzly and to create the best possible
working condition for the workers and maintain their wellness at workplace.
2. Defining the problem; with the needs of the workers and the standards and regulations say,
I define a problem statement as explained above, the goal for the response to the problem,
its objectives and also laying out the constraints of the design as also explained in previous
pages.
3. Gathering Information; this will include underground mapping, taking vent measurements
(volume of air, temperatures, humidity, ), dust sampling. This will include the survey
department, ventilation department and the geology department of Bulawayo Mining
company. Solutions to the similar problems are researched and also some background
research to the design.
4. Modelling (project design); here there will be development of functional specifications
(details of engineering design), system architecture, preliminary design specifications,
detailed design specifications and developing acceptance test plan.
5. Planning the project; with the Bulawayo Mining Company ventilation department putting a
helping hand, activities will be broke down to certain individuals which are part of the
project and the company management will be asked to help financially and in any way they
can to make the project a success.
Project management; departments to add value to the system include the survey,
ventilation, mine planning and the projects of the Bulawayo Mining company.
i) Work plan template
ii) Evaluation
iii) Plan template
iv) Budget
- Tasks broken down to team members involved in the project design.
Time factor; with the situation underground the project is way much behind hence the
system is supposed to be installed anytime now as soon as it is ready.
Assumptions and constraints;
i. assumptions
o the design will be able to deliver an output of fresh air perfect to ventilate again
ii. constraints
o Air from the design might be misty.
o There might be gasses still present in the output air.
6. Project delivery; this is whereby the system is installed, training of staff to operate the
system, performing of acceptance test, post project review and providing warranty support
then archive materials
7. Budget;
8. Project Team;
name qualification position department
Kubvoruno Pride Mining Engineering Student Mining Attachee Mining
Fabiyano E Assay
Muvhavhauri T Ventilation Officer Ventilation
Ngwenya Ventilation Officer Ventilation
Terrence Ventilation Officer Ventilation
Chokera T Diploma in Mining Mining Training Officer Mining