Metal Recycler Smothers Shredder Dust with High-Performance Suppression Unit

An innovative Midwest metal recycler is knocking down shredder dust with high-efficiency suppression equipment, helping operators to maintain production levels while protecting workers and the local environment from nuisance dust. Mounted in a rooftop location for better aiming, the powerful atomized misting unit delivers millions of droplets sized specifically for optimum particle attraction, supplementing the built-in water injection system in the firm’s hammer mill shredder. Remote control facilitates easy operation from the shredder cab, allowing the company to start, stop and oscillate the machine without physical contact.

Springfield Iron and Metal (Springfield, MO) is a privately owned scrap recycler that has been in business since 2008, processing both ferrous and non-ferrous scrap. The facility accepts aluminum, steel, copper, brass, alloys, iron and stainless steel in the form of aluminum cans, appliances, radiators, junk vehicles, construction steel and siding from businesses and consumers.

The company runs an American Pulverizer 80x104, a 4,000 HP machine capable of shredding 80+ tons per hour. The unit features integrated water injectors to control dust and prevent explosion hazards, as well as a closed-loop conveyor system to mitigate dust when materials go through the separator.

As part of its operating philosophy, Springfield Iron has fostered a commitment to environmental stewardship and employee safety, and company officials saw dust management as an integral part of that overall effort. “We wanted to incorporate the most effective suppression technology we could find to supplement our existing dust management techniques,” explained CFO David Braun. “When we had a chance to observe the DustBoss at another Midwest metal recycler, we felt like we’d found the right equipment,” he said.

The company specified a DustBoss® DB-45 from Dust Control Technology (Peoria, IL), the mid-sized unit in a family of atomized misting equipment designed specifically for dust suppression. Positioned over the shredder to knock down particles at the transfer point, the DB-45 helps control dust without over-saturating the shredded material.

“We experimented with a few different locations until we found the optimum spot,” explained Springfield Iron Plant Manager Burl Williams. “We now have it located on a rooftop approximately 50 feet off the ground, and about 40 feet from the shredder,” he said.

“The DustBoss has done a good job for us,” Williams continued. “And the remote control is a big advantage in our situation. It allows the shredder operator to manage the unit from his station, so no one has to visit the machine to start, stop or oscillate.”

The Equipment
The ducted fan design of the DB-45 features 18 brass nozzles, which atomize droplets to the optimum size for dust capture. “Airborne water droplets and dust particles attract more readily when they’re about the same size,” explained DCT President Edwin Peterson. “In our standard configuration, we atomize the water to 50-200 microns, which gives us the maximum attraction and avoids a slipstream effect. But we can customize the droplet sizes to suit specific applications.”

Peterson said that unlike many dust suppression products on the market, which are frequently adaptations of existing equipment, the DustBoss series is designed from the ground up for dust suppression. “To get the best performance, all of the components have to be designed to work together for optimum flow and distribution, with the right nozzles, spray angle, fan speed and delivery pressure to achieve the droplet size and velocity needed for dust management,” he explained.

Featuring a throw of 45 meters (147 feet), the DB-45 can deliver a virtual dust barrier that covers more than 70,000 square feet (approx. 6,503 square meters) when equipped with optional 359 oscillation. With its 15 HP (11.2 Kw) fan, the DB-45 generates 18,000 CFM (510 CMM) of air flow to maximize droplet distribution and particle capture. Like the more powerful DB-60, the design comes standard with adjustable elevation from 0-50.

All products in the DustBoss line are designed and built to deliver rugged durability, powered by a 3-phase motor with a service factor of 1.3. New units are covered by an industry-best three-year / 3,000 hour warranty, and customers can choose from purchase, rent or rent-to-own programs.