Case Study: Concrete and asphalt recycling plant stops fugitive dust

dust control recycling aggregate and concrete

“The plans for this facility were closely scrutinized by the regulatory authorities and local citizens.

We had to satisfy everyone that we had proven technology in place to run a very clean operation that wouldn’t contribute dust to neighboring wetlands or the community.

Without the latest dust suppression techniques, we would not have been able to do that.”

– Lou Gherlone
owner

Dust suppression misting technology has been a key element in allowing a new asphalt and concrete recycling plant obtain an operating permit, according to company representatives.

The permit will allow the facility to embark on a five year mission to crush local demolition waste into aggregate that can be processed and re-sold as clean fill material.

Spring Street Recycling (West Haven, CT, US) addresses the issue with several different dust suppression techniques, employing internal dust control that is integrated into its crushing operation as well as external, high-efficiency dust suppression equipment designed specifically to knock down airborne particles.

“The plans for this facility were closely scrutinized by the regulatory authorities and local citizens,” said owner Lou Gherlone.

“We had to satisfy everyone that we had proven technology in place to run a very clean operation that wouldn’t contribute dust to neighboring wetlands or the community. Without the latest dust suppression techniques, we would not have been able to do that,” he said.

 

Comprehensive dust control

The Spring Street Recycling operation starts in a Lippman Milwaukee 3062 primary jaw crusher, with a 200 HP electric motor. The unit features integrated dust control to suppress fugitive particles, with a series of spray nozzles mounted in the feed opening to provide internal and external saturation.

Even with a capacity of 400–500 tons per hour, the system uses only about two gallons of water per minute and contributes no runoff. From there, a 45-foot conveyor feeds a 62×202 triple-deck screen, with the material then entering a secondary crusher, a Lippman Milwaukee 5165 impactor with 300 HP engine that also incorporates internal suppression.

Gherlone knew that external control would also be needed for maximum effectiveness.

“We needed this facility to be built with the latest dust control technology, so it would meet even the strictest standards and satisfy everyone in the neighboring communities,” he said. Key to that effort is the DustBoss 60 (DB-60), a fully automatic high pressure misting system designed specifically for dust control.

recycling aggregate and concrete dust suppression
The oscillating ducted fan features 30 nozzles developed to atomize droplets to the optimum size for dust suppression—between 50 and 200 microns. With automatic oscillation and a powerful 25 HP motor generating 30,000 CFM, the unit has a 200-foot throw that can cover 21,000 square feet of area. The high-volume design includes an internal booster pump that delivers 150 PSI of pressure from a 2″ supply hose.

“We run the DustBoss whenever we’re loading or crushing,” Gherlone said. “It does a great job knocking down airborne particles, without over-saturating the material. The oscillation feature is a big advantage, as it allows us to cover far more area than a stationary design.”

The case for recycling concrete and asphalt

Reclaiming concrete and asphalt is more than good environmental practice; it makes good business sense.

“From every mile of concrete pavement of average thickness, nearly 6,000 tons of material can be reclaimed,” Gherlone said. “That means no landfill and no disposal fees. The resulting aggregate can be used as base material for new roads, footings and foundations, or it can be mixed into new asphalt or concrete,” he said.

Gherlone added that 44 states currently use recycled concrete as a road base. With asphalt, the motivation to recycle is even stronger.

“Asphalt pavement is 100 percent recyclable,” Gherlone said. “And research shows that the quality of recycled pavement is as good or better than virgin asphalt, even when recycled a second or third time.”

Recycling asphalt conserves resources such as natural aggregate and petroleum products, helping save taxpayers an estimated $300 million annually and reducing demand on sources of oil—a non-renewable resource.

In fact, recycling provides access to billions of gallons of petroleum contained in existing roads and highways, with roughly 4 million miles of pavement in the U.S. holding approximately 270 billion gallons of petroleum reserves.

CUSTOMER
Spring Street Recycling

LOCATION
West Haven, CT (US)

CHALLENGE
Implement comprehensive dust control techniques to address regulatory requirements and community concerns about a planned concrete and asphalt recycling plant, allowing the facility to earn its operating permit and assuring residents of its ability to suppress airborne particles.

SOLUTION
DB-60, in addition to the internal dust control from the company’s crushing equipment.

RESULTS
Facility owner Lou Gherlone was able to document the effectiveness of the site’s multi-pronged dust control approach, satisfying regulatory authorities and concerned citizens of the ability to suppress airborne particles and avoid risk to the community and local environment. The Spring Street Recycling plant successfully obtained its operating permit and is now processing about 2,000 tons per day of waste concrete and asphalt for recycling into saleable aggregate.

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