published regulatory change for mining facilities’ air quality related to respirable crystalline silica in April 2024, with changes taking effect June 17, 2024. Here, we’ll answer your most pressing questions to help you meet the MSHA respirable crystalline silica standard in your facility.

Navigate the proposed respirable crystalline silica standard with a proven partner. Talk with an �������� project engineer today. It’s the first step you can take toward meeting the proposed MSHA Respirable Crystalline Silica Standard.

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Transcript

Mining Ventilation Systems and Material Handling Equipment

In the mining industry, �������� provides industrial ventilation systems which include exhaust systems as well as make up air systems. In addition to ventilation systems �������� provides material handling equipment which include belt conveyors, bucket elevators as well as all the transfer chutes between all of the pieces of equipment. It is an advantage for ��������’s customers to use us to do both the industrial ventilation systems as well as the material handling equipment.

It is critical how both of those areas react with each other and interact. Silica exposure is a great concern in the mining industry. Proper industrial ventilation systems as well as material handling systems can greatly reduce the exposure level. With the combination of dust collection systems as well as make up air systems, silica levels can be reduced to a point where personnel can operate within facilities.

Knowledge and Experience with Mining Ventilation Systems

What sets �������� apart with industrial ventilation in the mining industry is we have knowledge and exposure to material handling equipment design, chute design, as well as the ventilation package. So even if you have an existing system, we can come in and make improvements to improve the dust collection as well as reduce silica exposure.

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Why Conduct an Industrial Ventilation Analysis

In an industrial ventilation analysis, we conduct an air quality survey by taking air readings of the ventilation system, as well as evaluate the dust collector, fans and all system components. From there, we develop a baseline rating of the entire system—a useful tool in determining what may need to be done, or not done, with your dust collection system. If you’re unsure whether an engineering study is right for you, here are the primary reasons to request an analysis.

Reason #1: Adding equipment

When adding equipment, you may need to expand the ventilation system. The best way forward is to start by evaluating the current system and its capacity. With that knowledge, you’ll then know whether your current system can handle more volume and how that may affect the collection volume from other equipment.

Also, adding equipment doesn’t automatically mean you need to add to your ventilation system. A ventilation analysis may show that you already have excess capacity. We may also be able to redesign the system to keep you from rerouting ductwork or buying a new dust collector.

Reason #2: Changing a manufacturing process

A manufacturing process change may mean greater particulate volume being directed to an area not equipped to handle the excess. If gone unchecked, particulate can build up in the ductwork, adding weight that can cause the duct to fail. And if the duct isn’t built to carry extra weight, facility damage and employee injuries may occur.

Reason #3: Becoming more energy efficient

Many companies are looking to be more environmentally conscious by using less energy. Even though an older dust collection system continues to do the job well, it may be costing more to run. Older fans, for example, can be a culprit. An engineering survey would show whether you could save energy and money with newer, more efficient equipment, depending upon your system design and layout.

Reason #4: Becoming silica standard-compliant

The silica standard is a high bar. If silica is part of your manufacturing process and you are having difficulty meeting the standard, there are a couple of things you should do. First, hire an industrial hygienist who will analyze your facility for silica risk. For example, the hygienist will take samples for every employee in every area of your plant for every shift. Once you have that information, we can then conduct an engineering study to review your entire system and determine how best to capture the silica.

What to Expect When Your Industrial Ventilation Analysis is Complete

Once we take the air quality survey readings and inspect your system, we develop a comprehensive written report of our findings. You’ll receive data on your equipment and ventilation system with indication of whether it’s collecting particulate effectively and where improvements, if any, are needed. We then:

• Request a follow-up meeting to discuss areas that need improvement
• Develop a conceptual design
• Develop a proposal that includes our costs based on our design
• Once agreed upon, implement the solutions

Getting an engineering study done is much like going to the doctor—it helps ensure everything is operating the way it should. If you believe an industrial ventilation analysis would benefit your company, contact us to schedule a survey.

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Hood Types

Enclosing hoods:

An enclosing hood will completely or partially surround the point where contaminants are generated. An enclosing hood is typically preferred but may not be practical due to potential interference with employee workstations.

• A partial enclosing hood has two to three sides where an inward flow of air through the opening will contain the contaminant within the enclosure and prevent its escape. Examples include paint spray booths or grinder station.
• A completely enclosing hood has all sides and is preferred whenever possible. A laboratory hood is an example of this use.

Exterior hood:

Exterior hoods are placed next to the point where contaminants are generated without creating an enclosure. An exterior hood may be an opening on a welding table or slots on the side of a tank. The exterior hood should be located in the path of the emission if transferring larger particulates such as sand.

There are four main types of exterior hoods:

• Canopy: A one- or two-sided overhead hood that receives upward airflow from hot air or gas.
• Close-capture: Mounted directly over the source of a contaminant.
• Push-pull: A hood placed on the side of a push-pull ventilation system.
• Side-draft (also called lateral exhaust hood): This is not as efficient as other containment or down-draft hoods.

Hood Velocity Considerations

A specific velocity is required, depending on the type of contaminant being captured. To achieve the required velocity, carefully consider the hood’s shape, size and location.

• Face velocity: Velocity right at the hood opening.
• Capture velocity: Velocity at the dust generation source to capture the contaminant and transfer it into the hood.

Ergonomic Considerations:

An industrial ventilation system hood is one of the most important components of an individual’s workstation. A worker will be more likely to use the hood and the ventilation system properly if ergonomic elements are considered. Among these considerations are:

• Accessibility to parts within the hood
• Size, design and weight of objects handled
• Safety cables
• Overhead clearance
• Sharp edges
• Lighting
• Ease of cleaning

���ձ�’s engineering and design team has years of experience designing and sizing industrial ventilation systems.  �������� can assist in the design of a new system or the redesign of an existing system.

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Calls for Combustable Dust Standards

OSHA had been expected to issue a standard in the first half of 2014, but it missed that deadline. But according to its schedule for the remainder of the year, OSHA now expects to deliver a standard under the Small Business Regulatory Enforcement Fairness Act in December.

The CSB has been calling for this standard since 2006. More recently, CSB chairman Rafael Moure-Eraso called for the standard in July after the publication of a final report into the .

The ALS facility milled and processed scrap titanium and zirconium into dense disks called “compacts.” A fatal explosion at the plant seems to have started after sparks from metal-to-metal contact ignited metal powder in a faulty metal blender used to process zirconium. The CSB has created a to show how the accident may have unfolded.

After the release of that case study, Mr Moure-Eraso said the CSB “believes it is imperative for OSHA to issue a comprehensive combustible dust standard for general industry with clear control requirements to prevent dust fires and explosions.”

, “Most solid organic materials, as well as many metals, will explode if the particles are small enough, and they are dispersed in a sufficient concentration within a confined area, near an ignition source.”

And he cautioned that even “seemingly small amounts of accumulated combustible dust can cause catastrophic damage.”

In , the CSB notes that accumulated dust of about 1/32^nd of an inch, or the thickness of a dime, covering 5% of a room area is enough to fuel a “catastrophic explosion.”

Materials that can Make Combustable Dust

A wide variety of materials that can be :

• Food (e.g., candy, sugar, spice, starch, flour, feed)
• Grain
• Tobacco
• Plastics
• Wood
• Paper
• Pulp
• Rubber
• Furniture
• Textiles
• Pesticides
• Pharmaceuticals
• Dyes
• Coal
• Metals (eg, aluminum, chromium, iron, magnesium, and zinc)
• Fossil fuel power generation, such as coal-fired power plant

Components of a Combustable Dust Explosion

And five things need to come together for there to be a dust explosion:

• Combustible Dust (Fuel)
• Oxygen (Air)
• Ignition Source (eg, electrostatic discharge, electric current arc, glowing ember, hot surface, welding slag, frictional heat or flame)
• Dust Suspension in air exceeding the minimum explosive concentration (MEC)
• Confinement (eg, vessel, room, building, ductwork)

Mr Moure-Eraso’s called again for the combustible dust standard in an August in the New York Times, in which he described dust explosions as “readily preventable with engineering controls, ventilation, training and other measures.”

He recommended that voluntary, industry-supported national fire codes be codified and enforced through federal regulations.

Those codes include the ’s recommendations that companies:

• Control fugitive dust emissions;
• Design Facilities to prevent dust from migrating and accumulating; and
• Perform rigorous housekeeping to remove any dust that does build up.

Combustable Dust Regulations: What’s Next?

Responding to the CSB’s calls for action in this area, an OSHA spokesman told in early September, “We are continuing our efforts to move forward on combustible dust rulemaking, and OSHA has also put special emphasis on controlling combustible dust hazards through a national emphasis program, education and outreach.”

OSHA says it will use the information gathered from (NEP) in 2008 to produce the standard now expected in December.

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