Comparative study of cost-benefit integrated system of water spary with industrial ventilation and bag filters in a minerals processing company

Control of fugitative dust from mining process and application of an appropriate and economical system for dust collecting is essential. The goal of this study was cost-benefit analysis of an integrated systems and compare to bag filter in a crushing plant of a mining company.
A local exhaust ventilation system for capture of emitted particlees, a water spray for dust suppresion at sources and parallel Stairmand model cyclones as dust colletor were designed and installed based on the standards and guidelines. Then, efficiency of wetting and industrial ventilation system for control of ambient dust personal exposure and environmental emission have evaluated as integrated and alone. Finally, cost-benefit analysis of this system was compared to bag filter.
The efficiency of this system for control personal exposure repairable particles and emitted dust to ambient air was 87% and 95% for plant 1 and 88% and 95% for plant 2, respectively. The concentration of emitted emitted dust from stack to environment were 121.28 mg/m3 and 112/68 mg/m3 for plant 1 and 2, respectively. The capital, operational and maintence costs of this option was 217 and 0.992 billion rials lower than bag filter. Also, annuall collected dust by cyclones was worth 518 million rial.
According to results, integrated system had a significant impact on emitted dust in workplace and environment. The economical analysis domonstrated 73% and 80% savings in capital and operational costs compared to bag filter. Total costs of implented project will be compensated at 220 day with recovered dusts, therefore, in the same condition, it can be suggested as the favourable and economical solution.