1. PAINPOINT DRIVEN OPENING

Managing dust control in limestone mining operations is a persistent challenge with significant operational and financial consequences. Uncontrolled dust leads to excessive wear on conveyor systems, crushers, and screening equipment, increasing maintenance costs by an estimated 1525%. It creates compliance risks with environmental and workplace health regulations, potentially resulting in fines and operational shutdowns. Furthermore, product loss as airborne fines directly impacts yield and revenue. Are you struggling with high filter replacement frequency on baghouses? Is your water truck fleet consuming excessive fuel and manhours for minimal dust suppression effect? A modern, engineered solution is required to mitigate these costs and protect both your assets and your workforce.

2. PRODUCT OVERVIEW

The EcoFriendly Limestone Mining Dealer refers to a specialized portfolio of highefficiency, modular dust suppression and collection systems engineered for quarry and processing plant environments. The operational workflow is designed for integration into existing material handling points: (1) Targeted mist or foam application at primary crusher discharge, (2) Enclosed transfer points with passive ventilation, (3) Capture at conveyor loading zones via local extraction hoods, (4) Filtration through a centralized baghouse or cyclone system, and (5) Clean air return to the environment. This solution is scoped for continuous operation in limestone processing from primary crushing to final loadout. Its primary limitation is the requirement for a consistent power source and planned maintenance intervals for filter media.

3. CORE FEATURES

Intelligent Atomization Nozzle System | Technical Basis: Highpressure, ultrasonic droplet fragmentation | Operational Benefit: Produces micronsized water droplets that bind to dust particles without overwetting material, preventing belt slippage and ratholing in silos | ROI Impact: Reduces water usage by up to 60% compared to standard spray bars, lowering water procurement and haulage costs.

Modular Capture Hood Design | Technical Basis: Computational Fluid Dynamics (CFD)optimized airflow | Operational Benefit: Creates effective containment at transfer points with minimal impact on belt loading capacity or material trajectory | ROI Impact: Cuts fugitive dust by over 95%, reducing cleanup labor and extending downstream equipment life.

PTFE Membrane Filter Bags | Technical Basis: Surface filtration with low pressure drop | Operational Benefit: Provides superior fine particulate capture (<5µm) while allowing for efficient pulsejet cleaning cycles | ROI Impact: Increases filter service life by 3050% compared to standard felt bags, lowering consumable costs and maintenance downtime.

Variable Frequency Drive (VFD) Fan Control | Technical Basis: Realtime pressure drop monitoring across the filter system | Operational Benefit: Automatically adjusts fan speed to match actual system load, optimizing energy consumption | ROI Impact: Field data shows typical energy savings of 2035% on fan motor operation.

Centralized PLC & Remote Monitoring | Technical Basis: Industrial IoT sensors for pressure, flow, and motor amperage | Operational Benefit: Provides operators with realtime system health data and predictive maintenance alerts via HMI or secure portal | ROI Impact: Enables conditionbased maintenance planning, preventing unplanned stoppages and reducing service call frequency.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | EcoFriendly Limestone Mining Dealer Solution | Advantage (% improvement) |
| : | : | : | : |
| Water Consumption (Liters per ton processed) | Highvolume spray bars / Water trucks | Intelligent atomization & foam systems | 5565% reduction |
| Specific Energy Consumption (kWh/1000 m³ air filtered) | Fixedspeed fan on old baghouse design | VFDcontrolled fan with lowdrag filters| 2535% reduction |
| Filter Bag Service Life (Operating months) Standard limestone dust conditions.| 1218 months (standard polyester felt)| 1830 months (PTFE membrane)| ~50% increase |
| Captured Particulate Size (Efficiency at given micron)| 99% at >10µm typical for older cyclones| 99.9% at >2µm per ISO test standards| Significantly finer capture |

5. TECHNICAL SPECIFICATIONS

System Capacity: Configurable from 10,000 CFM to 100,000 CFM air volume.
Power Requirements: Dependent on configuration; typical range 30kW 350kW main fan motor; 400V/50Hz or 480V/60Hz threephase.
Material Specifications: Primary ductwork & hoods constructed from galvanized or abrasionresistant steel; stainless steel options available for highmoisture areas.
Physical Dimensions: Modular design; central filter units range from ~6m L x 4m W x 5m H to 15m L x 8m W x 10m H.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; humidity resistant electrical components; NEMA 4/4X enclosures standard.

6. APPLICATION SCENARIOS

LargeScale Aggregate Quarry & Processing Plant

Challenge: A major quarry faced escalating costs from water truck operations for haul road dust control and frequent downtime replacing clogged filter bags on their primary crusher baghouse.
Solution: Implementation of a centralized EcoFriendly Limestone Mining Dealer system featuring targeted foam suppression at the crusher outlet and VFDcontrolled extraction across six key transfer points.
Results: Reduced water truck deployment by 70%, saving over €85,000 annually in fuel and labor. Filter change intervals extended from 14 to 22 months. Achieved consistent compliance with site boundary particulate monitoring limits.

Lime Manufacturing Plant – PreKiln Processing

Challenge: Excessive fine limestone dust loss at feed stockpiling and raw mill feed systems was impacting product yield and creating hazardous housekeeping conditions.
Solution: Installation of modular capture hoods with local cyclone preseparators feeding into a new highefficiency baghouse unit.
Results: Recovered an estimated 1.5 tons of saleable material per day. Improved indoor air quality metrics by over 80%, meeting stringent occupational exposure limits.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Systems are projectquoted based on required CFM capacity:
Tier I (60k CFM): Turnkey plantwide dust management systems including ductwork design & installation supervision.
Optional Features: Explosion venting & suppression systems; heat recovery modules; advanced emissions monitoring packages; sound attenuation enclosures.
Service Packages: Annual inspection & performance audit; guaranteed spare parts availability contracts; fullservice maintenance agreements including filter replacement.
Financing Options: Equipment leasing structures through partner financial institutions; rentaltoown programs for pilot installations; project financing available for largescale turnkey projects.

8. FAQ

1. Q: Is this system compatible with our existing baghouse infrastructure?
A> In many cases yes retrofits are feasible Our engineering assessment focuses on integrating new capture hoods ductwork VFD controls or updated filter media into your existing collector structure often providing a costeffective upgrade path

2 Q What is the typical implementation timeline from order to operational status
A For a standard modular system lead time is typically weeks Factory acceptance testing can be conducted For complex plantwide systems detailed engineering procurement construction phases usually require months depending on scope

3 Q How does this solution impact our ongoing operational manpower requirements
A The systems are designed for automated operation requiring only routine monitoring Maintenance demands shift from frequent manual cleanup labor towards scheduled technical servicing which can often be managed by your existing plant maintenance team

4 Q Can you guarantee compliance with our local environmental regulations
A While we cannot provide legal guarantees our systems are engineered to meet stringent international emission standards such as EU BAT We provide performance test reports based on ISO methodologies which form the technical basis for regulatory submissions

5 Q What are the critical factors affecting longterm filter life in this application
A Key factors include maintaining proper compressed air quality dry oilfree for pulse cleaning ensuring inlet gas temperature remains within design limits avoiding condensation inside the collector through insulation or trace heating where needed