DUST CONTROL SYSTEMS
Containment
Material containment and spillage typically accounts for more than 75 percent of the fugitive material in the workspace. Fugitive material escaping conveyors, transfers, crushers, screens or other equipment has a huge impact on operating, cleanup, maintenance, lost-production and other costs.
The Engineering & Design Division has modernized over 3,500 conveyors and other material transfer equipment to eliminate spillage, carryback and leaks.
Dust Management
The Engineering & Design Division uses science and proven, specialized techniques to provide solutions for dust, spillage and fume control. Every material transfer and process system is unique. Therefore, root causes of dust and spillage must be identified for each source and addressed individually.
We strive to create workspace dust levels below regulatory limits for healthier, safer and more productive work environments. Dust management includes the integration of Material Containment with passive or active collection systems, fogging or suppression systems. Our objectivity enables us to evaluate the technical, operational and maintenance impacts and select the best dust control system for our client’s specific needs.
We seek to provide our customers with dust emission control systems that meet and exceed their expectations by offering performance objectives such as No Visible Dust® on newly installed or upgraded dust control systems. To satisfy these objectives requires considerable attention to detail and quality control during all phases of a project. |
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Technologies
The Engineering & Design Division integrates many technologies into overall projects depending on client needs. Some of these are Discrete Element Modeling (DEM), Dust Analyst®, Fire Protection Engineering, automated washdown systems, tripper automation, bunker and silo management (flow), dust collection, dust suppression, belt cleaning and material containment. Our unique position of not being a manufacturer allows us to apply multiple technologies for the best overall solutions. |
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Vari-Load® Transfer System
(Patent Pending)
The Vari-Load® Transfer System is a breakthrough technology for controlling fugitive dust emissions from bulk solids handling transfer operations. This system adapts to various material conditions and capacity / tonnages. The frontal wall adjustability allows the transfer to accommodate varying material characteristics, wet and cohesive or dry and dusty, while dramatically reducing induced air, the root cause of fugitive dust. Added benefits are the adjustable lower chute which center loads the materials on the belt and the hinged unloading terminal (head chute) which allows for ease of inspection and maintenance.
Click here for PDF brochure.
Click here to view 4 minute Before & After Installation. |
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Dustless Transfer® System
The Dustless Transfer System is based on induced airflow recirculation technology and has proven to reduce workspace dust levels so that no respirators are needed. This patented system controls dust passively without need for dust collection or suppression.
Click here for PDF brochure. |
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Discrete Element Modeling (DEM)
Discrete Element Modeling (DEM) is a sophisticated computer technology used to study material movement and interaction to predict the material flow achieving an optimum chute design. DEM enables us to accurately predict material behavior during the design process for center loading as well as dramatic reductions in dust, belt wear, noise and chute wear.
Click here for PDF of Discrete Element Modeling brochure for information. |
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Dust Analyst® Program
Our proprietary computer model, the Dust Analyst® Program, provides a rational approach to calculate total system requirements based on clearly defined data obtained by considering all factors involved. We look at induced air, determined by fluid dynamic models of tonnage; particle distribution (size) and fall height; captured air, measured by multiplying the area of all openings by required capture velocity; displaced air, determined by the rate of displacement of air by particulate inside the containment housing; and air generated by rotating members (crushers) throughout the system. Dust Analyst enables more accurate design resulting in cost saving installation, operation and maintenance.
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Dust Collection
Many existing dust collection systems don’t meet the expectations of their operators. Most of them were doomed to fail from the very beginning because they weren’t engineered, rather simply put together by general contractors without respect for the total system. The proprietary Dust Analyst® rational analysis program enables proper determination of collection volume.
CCC Group, Inc. Engineering & Design Division takes every detail in to consideration when engineering a dust collection system. From ducting to bag cleaning to dust disposal, we provide a properly designed, highly reliable and low maintenance Dust Collection System.
Click here for PDF of Dust Collection brochure for information. |
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Automated Washdown Systems
Over time, superfines settle and collect on walls, beams, pipes, machinery and floors…virtually every surface in the facility. Washdown is the only solution to these hazardous and unhealthy materials.
The Engineering & Design Division adds engineering to the development and implementation of automated washdown systems. Experience is key to designing and installing an effective system.
Washdown systems can be very complex, consisting of multiple piping zones, sprayheads and controls, designed and integrated into the unique application of each individual facility. We take every aspect of the project into consideration: available water pressure; drainage capacity; evaluation of plant operations to effectively sequence the system; proper selection and location of sprayheads and controls; and dirty water disposal requirements
Click here for PDF of Automated Washdown System brochure for information. |
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Glider Roller Belt Support® System
Controlling fugitive materials while bulk solids are being transferred is critical for creating safe and efficient operating conditions. Typically, spillage and airborne pollution are created at transfer points as induced air, material impact and vibrations occur.
The Glider Roller Belt Support System technology meets the challenge of containing fugitive materials on conveyor belts at transfer points with small diameter, closely spaced high speed rollers and slide plates which prevent spillage and belt sag.
Adjustable wing roll segments allow the roller bed to be integrated with any manufacturer’s idlers and conveying system. Additionally, they have three standard hole positions to accommodate 20°, 35° and 45° trough angles.
Rollers that maintain contact with the belt reduce drag which reduces horsepower needs and potential heat build up with components.
Click here for PDF of Glider Roller Belt brochure for information. |
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Piercing Rod
The Piercing Rod technology was developed to safely extinguish “hot spots” in volatile bulk solids material storage areas. After extensive research and development, this product was engineered as part of a total solution approach for safe conveyance and storage of bulk solids.
The Piercing Rod and the F-500 fire suppression agent form a unique combination that works six times faster and requires one-sixth the retardant than other typical suppression products such as wetting agents and foams. It delivers the suppressant directly to the targeted area and forms a “chemical cocoon” around the ignited materials, depriving the fire of oxygen and halting heat-generating free radical activity – in effect snuffing the fire before it becomes catastrophic.
F-500 is non-corrosive, non-toxic, non-hazardous and biodegradable, resulting in minimal cleanup after ignited materials are suppress.
Click here for PDF of Piercing Rod brochure with additional information. |
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Overview
Multi-discipline Engineering & Design Solutions
Conceptual ♦ Mechanical ♦ Structural ♦ Civil ♦ Electrical
Procurement & Material Expediting
Project Management & Quality Controls
The Engineering & Design Division exists for the express purpose of providing the best available technologies and most objective analysis for your operational challenges. We are a single-source provider for all engineering disciplines, project management, supply and construction.
Our qualified team competently applies an unequaled “total solution” approach to hazards that have plagued bulk solids transport and storage systems for decades. CCC provides a single-point source for all dimensions of Dust Control & Material Transfer Technologies.
DUST CONTROL SYSTEMS
The Engineering & Design Division provides industry leading dust and fume control systems with proven results. We deliver innovative, turnkey solutions for complete material transfer risk management. Our approach is unique in that we are an unbiased engineer equipped with the best methods and technologies available. We utilize passive dust control techniques, wet and dry active dust collection, suppression or fogging, coupled with material containment systems and automated washdown systems. We offer best available design and technology to solve even the most complex operational challenges.
We help our client to create a clean, more productive and healthier work environment, by increasing operational efficiencies and profitability. Our total solution and holistic approach achieves superior results by following proven methods for project planning, management and evaluation – methods that translate into long-term sustainable solutions.
Our bulk material experience includes PRB coal, Eastern coal, Lignite coal, limestone, gypsum, ash, bauxite, alumina and other alternative fuels and biomass. Whether retrofit solutions for existing facilities or new greenfield projects, dust management to innovative material transfer technologies, CCC Group is committed to cost effective, long term solutions.
Technologies
Discrete Element Modeling (DEM) - Material flow analysis
Dust Analyst® Program - Analyze airflows for dry and wet dust collection systems
3D AutoCAD® - Visualization of complex geometries
SolidWorks® - Increase productivity / design time reduction
Vari-Load® Transfer System – Automated material flow adjustment
Dustless Transfer® System – Passive dust control system
Glider Roller Belt Support® System – Low friction belt support system
Piercing Rod – A safe, effective, non-toxic and biodegradable method for extinguishing bunker fires
Best Available Control Technology (BACT) Components and Systems – We have been recognized as having BACT by the Wyoming, Texas and Iowa State Department of Environmental Quality (DEQ) Agencies.
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Services
Multi-discipline Engineering & Design Solutions
Conceptual ♦ Mechanical ♦ Structural ♦ Civil ♦ Electrical
CCC Group, Inc. Engineering & Design Division analyzes and defines operational challenges, conceptualizes solutions, provides Best Available Technology, cost estimates, detailed drawings and specifications to meet our client’s specific project needs. Our staff is dedicated to providing cost effective, long-term solutions and value to our clients.
Procurement & Material Expediting
Close interaction between our in-house Procurement and Project Engineering teams allow for fast and accurate order placement of equipment and fabrication. Moreover, coordination of all ordering, shipping and expediting leads to quality control and timely delivery of materials to site to meet project deadlines.
Project Management & Quality Controls
Our Project Management Team is dedicated to providing the experience and leadership necessary to ensure safe, on-time and on-budget projects. We believe developing close relationships with our clients enables a seamless efficiency in providing solutions to operational challenges and add value and quality throughout the execution of projects.
Our services are offered on any level of involvement based on the projects needs and client preference:
- Engineering Only - E
- Engineering & Procurement / Supply - EP
- Engineering, Procurement / Supply & Construction Management - EPCM
- Engineering, Procurement / Supply & Construction - EPC
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