Crushing operations in material yards are a key link in the processing of raw materials such as ores and coal. However, a large amount of dust generated during the crushing process spreads throughout the work area, which not only reduces equipment accuracy and shortens service life, but also puts on-site workers in a difficult situation of being “surrounded by dust”. Traditional dust control methods either rely on fixed spray devices that cannot move with the crushing points, or require manual on-site operation, which is not only inefficient but also has potential safety hazards. The long-range industrial fog cannon, with its core advantages of “remote control + wide-range coverage”, provides a new solution for dust control in material yard crushing.
The core highlight of the long-range industrial fog cannon is that it breaks through spatial limitations. Workers can uniformly dispatch multiple fog cannons within a 500-meter range through an intelligent platform in the central control room or a handheld remote control. Whether adjusting the spray angle, range, or switching working modes, real-time responses can be achieved. Aiming at the frequent movement of crushing points in material yards, the equipment supports presetting multiple operation points. When the crushing equipment is moved, the fog cannon can automatically switch to the spray parameters corresponding to the target point without manual on-site adjustment.
For example, a large ore material yard in Spain has 3 crushing areas. In the past, 3 workers had to be assigned to operate spray equipment separately, and due to excessive dust, workers had to evacuate frequently. After introducing long-range industrial fog cannons, one central control worker can manage 3 devices at the same time. Through cameras, they can observe the dust situation in real time and accurately adjust the spray intensity. This not only reduces labor costs but also avoids the risk of workers being exposed to high-dust environments.
The on-site crushing environment in material yards is often accompanied by harsh conditions such as high dust, strong vibration, and alternating high and low temperatures. The long-range industrial fog cannon has been specially enhanced to cope with these challenges. The machine body is welded with 16mm thick wear-resistant steel plates, which can resist the impact of ore debris. The spray pump is an industrial-grade high-pressure pump that can operate stably in an environment with a dust concentration of up to 500mg/m³ and is not easy to block. The equipment is also equipped with a constant temperature heating system, which can prevent pipeline freezing even in a low-temperature environment of -20℃, ensuring normal operation in winter.
In terms of dust control efficiency, its range can reach 20-120 meters, and the maximum spray volume is 120L/min. It can form a “fog curtain” covering an area of over 10,000 square meters, firmly confining the dust generated by crushing within the work area. At the same time, the diameter of fog particles can be accurately controlled between 50-150 microns, which can not only efficiently absorb dust particles but also avoid raw material moisture and caking caused by excessively large fog particles, perfectly balancing dust control effect and raw material protection.
A coal material yard in the Philippines was repeatedly notified by environmental protection departments due to crushing dust problems. This material yard crushes more than 2,000 tons of coal every day, and the dust concentration can reach up to 800mg/m³ at its peak. This not only caused the withering of surrounding vegetation but also led to frequent damage to the bearings and motors of crushing equipment, with monthly maintenance costs exceeding 80,000 yuan. The previously tried fixed spray system had a dust control effect of only 30% because it could not move with the crushing points.
Last year, the material yard introduced 6 long-range industrial fog cannons and built a dust control model of “zoned management + linked response” through the central control platform. When the No. 1 crushing area is activated, 2 corresponding fog cannons in that area automatically turn on and form an annular fog curtain at a 45-degree elevation angle. When the crushing equipment moves to the No. 2 area, the system automatically shuts down the equipment in the No. 1 area and starts the fog cannons in the No. 2 area. At the same time, the dust sensor equipped on the equipment monitors the concentration in real time: when the concentration exceeds 150mg/m³, the spray is automatically strengthened; when it is lower than 50mg/m³, the spray volume is reduced.
After 3 months of operation, the dust concentration in the crushing area of the material yard has stabilized below 40mg/m³, meeting national environmental protection standards. The surrounding vegetation has gradually recovered, and the number of residents’ complaints has dropped to zero. The maintenance frequency of crushing equipment has decreased by 70%, saving about 56,000 yuan in monthly maintenance costs. More importantly, due to the reduction in dust, workers no longer need to wear heavy dust masks, and work efficiency has increased by 25%.
The difficulty in dust control for material yard crushing lies in how to achieve efficient, safe, and sustained management in dynamic operation scenarios. The long-range industrial fog cannon breaks spatial limitations through remote control and adapts to harsh environments with industrial-grade configurations, transforming material yard crushing operations from “dust-filled” to “clean and efficient”. When a remote command is issued and the fog curtain unfolds over the crushing point, it not only blocks the spread of dust but also protects the ecological environment and workers’ health, becoming an important support for green production in material yards.
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