Local experts weigh in on safe and efficient dust suppression

Compiled by Sharyn Macnamara

Without effective dust control, mining operations face increased health costs, higher equipment maintenance expenses, possible production downtime, significant regulatory penalties and potential damage to local ecosystems and reputation. Local experts share technical and process insights to assist mines in managing dust suppression.

Dust is a universal problem and unavoidable in the excavation and movement of the earth and its minerals. Although often perceived as a “grudge purchase”, dust suppression is a “process” critical to protect workers’ health against respiratory illnesses such as silicosis and pneumoconiosis; to prevent accidents by maintaining visibility; to ensure compliance with stringent local and international air quality and environmental regulations; to improve operational efficiency by reducing equipment wear and downtime; and to demonstrate care and responsible resource extraction to communities in safeguarding the environment and supporting long-term industry sustainability.

 

Safety, regulation and progress

Fillipus Masipa, group chief technical officer at DUST-A-SIDE – a South African company with an international footprint in dust management services including dust and road management for opencast and underground mines, rural and community roads, process plants and construction and agricultural sectors – explains that current regulations define the occupational exposure and permissible exposure limits for various dust categories, from nano and ultrafine particles to respirable, inhalable, total suspended particulate matter (TSPM) and dust fallout.

Ritesh Seecharan, Sales and Marketing consultant at CDC Dust Control – a developer and manufacturer of components for integrated dust suppression systems used on continuous miners and road haulers, in mining applications and other industries – adds that studies by the National Institute for Occupational Health (NIOH) show persistently high rates of respiratory diseases like silicosis and tuberculosis among miners. He notes, “Underground mining operations have made notable progress due to stricter regulatory frameworks, including enforced ventilation standards and real-time dust monitoring. However, surface mining operations lag behind, especially in areas like stockpiling, haul roads and transportation.” He emphasises that the lack of comprehensive dust control in these zones allows fugitive dust to escape into surrounding communities, posing risks not only to mine workers but also to rural and urban populations living near mining corridors. “This regulatory imbalance means that while underground miners may benefit from improved safety, the broader population remains vulnerable to airborne particulate matter.”

Masipa adds another challenge – the consistent enforcement of these standards. The “polluter pays principle” (PPP) as is enshrined in the South Africa National Environmental Management Act (NEMA) dictates that those responsible for pollution should bear the costs of its prevention, control and remediation. “Effective enforcement and the willingness of polluters to take responsibility, either by implementing dust control measures themselves or by contracting competent companies specialising in dust management, can indeed make a significant difference in the mining industry.”

 

Efficiency and the latest trends

It makes sense for an operation to control dust not only from a safety and regulatory point of view, but from an efficiency standpoint. “Dust hampers the movement and efficiency of dump trucks and other related production equipment, leading to slower operations and reduced overall productivity,” says Masipa.

He notes that the latest and most effective trends in managing dust in mining include but are not limited to:

• The use of Artificial Intelligence (AI) – to predict potential dust events and automate dust suppression intervention measures to proactively manage the situation as opposed to conventional reactionary approaches. Anticipation of dust hotspots aids to optimise the deployment of dust suppression resources minimising water and energy consumption.
• Using sustainable and eco-friendly dust control solutions –such as fog-based dust suppression systems is particularly beneficial for managing airborne dust around moisture- sensitive materials. These systems operate at high pressures and use minimal water, making them environmentally friendly while effectively controlling dust at material handling points such as conveyor discharge areas, screens and tipping bins. When combined with eco-friendly surface-active agents, these systems can generate ultra-fine fog capable of capturing even the finest dust particles, including TSPM.
• Deployment of IoT and sensor technology – the installation of tailored sensors to monitor the performance of both treated and untreated roads, as well as their impact on the hauling fleet. Additionally, dust monitors equipped with sensors and live dashboards enable continuous collection, analysis and response to real-time data, supporting proactive decision- making and improved operational efficiency.

Masipa emphasises a Hybrid Dust Control Approach – a tailored, and cost-effective solution designed to meet customer-specific needs and budgets. “This approach is driven by ongoing research and development and involves the use of eco-friendly dust palliatives to reduce the risk of contaminating open water bodies and mitigate associated ecological damage.”

Seecharan, adds that Mist Spray Systems which atomise water into fine droplets that agglomerate (bind) with airborne dust particles can be automated for energy efficiency, and are effective in localised areas, but they require a consistent water supply and regular maintenance. Mist/Fog Cannons, on the other hand are used for large open areas and can project mist over long distances, effectively suppressing dust during stockpiling, loading and hauling. However, he notes that the high upfront cost and perceived complexity often deter adoption, despite proven effectiveness.

“Unfortunately, many operations still view these technologies as non-essential expenses, rather than long-term investments in health, compliance and community safety. Fugitive dust from surface mining is not confined to the mine itself. It travels through wind, vehicles and erosion into homes, schools, and agricultural zones. This exposure increases the risk of chronic respiratory diseases among the general population, including children and the elderly. Dust suppression must be seen as a core operational responsibility, not a discretionary line item. The health of our miners and indeed, all South Africans depends on it,” says Seecharan.

 

Money saving

Nolte Smit, Sales and Marketing manager from Chemicals and Research – one of the major independent manufacturers of synthetic resins in southern Africa – explains that despite being viewed as a “grudge purchase”, correct dust suppression practices can actually save an operation money in the long term through reduced maintenance and longer equipment life, fewer environmental impacts and improved public perception – all cost- saving advantages that ultimately affect the bottom line. “Most savings come from reduced wear and tear on equipment – fewer breakdowns, cleaner filters and longer vehicle life,” says Smit. Dust gets into everything: filters get clogged, hydraulic cylinders and seals get damaged, and grease becomes contaminated, leading to leaks and unexpected breakdowns.

“However, simply spraying clean water is not dust suppression. Water only works until it evaporates – which can be as quickly as within one minute.’’This is a waste of a precious resources, time and money, in Smit’s view. He believes dust suppression is a “process and that there is no ‘one-size-fits-all’ solution”. The efficiency of the solution is linked to a combination of the right method and binder designed for a particular environment – and this must be monitored and adjusted daily. He explains that binders fall into two broad categories – dissolvable binders which do not form a permanent bond or crust (when new binder is applied, it dissolves the existing layer) and insoluble binder, which bind dust particles and eventually form a solid crust on a road (more durable with limited rain impact on the treated surface). “Even the best dust suppressant will fail if applied incorrectly – nozzle design, spray pattern and application rate are critical,” says Smit. Community involvement, he adds is key and beneficial –“Allow the local community to help manage the process and apply the suppressant. Train individuals and pay them a fixed monthly fee to do so – this creates ownership, supports job creation, and encourages sustainability.”

 

Evolution

Sarel du Plessis, managing director of Flowcentric Mining, Northern Cape – which offers durable, environmentally friendly solutions to manage wastewater evaporation, road and material handling dust, and control of spontaneous combustion hazards on mine sites – explains that the latest developments in dust suppression include precision product application on haul roads. “Over the years, dust suppression has evolved from conventional water tankers spraying water to precision product application with dust palliatives and binders. “The introduction of blended dust palliatives and products is also showing benefits. Blended products with different characteristics help reduce dust suppression intervals and improve road quality.”

“This is done by using GPS, variable pumps and nozzles. Product application done with water bowsers are now applied at the optimum amount of product per m² as the application rate adjusts according to truck speed. Not only does it result in optimum and effective dust suppression, but it also eliminates ‘over wetting’of roads and the hazards this creates. GPS mapping makes it further possible to apply product where intended. This technology automatically opens and closes sprayers when the truck passes the designated route.”

He adds that in materials handling plants foam has been introduced to replace the conventional spraying of water on conveyor belts and transfer points. Using foam reduces water consumption which reduces clogging of chutes while still being an effective method for dust suppression. Introducing high-pressure, low-volume dust suppression systems in materials handling plants has made great strides.

“A product has also been developed to suppress dust in areas not easily accessible, like tailing dams and stockpiles where conventional dust suppression was not previously possible. It can now be done with a product that binds dust but still allows water to seep through to stimulate vegetation growth.

“All of these technologies are not only beneficial to the mining industry, but the agricultural industry is also starting to use these technologies to improve production.”

 

Challenges

Climate change and resources are a matter of concern, says Du Plessis. “Water remains a major resource used in dust suppression and although product technology reduces water consumption, it remains scarce in southern Africa.” In water-scarce areas or areas with inclement weather, especially long dry summers and strong winds, managing dust levels always remains a challenge. Climate change and global warming is a growing concern and as ambient temperatures rise, new methods and technologies must be developed.”

Coenie Pretorius, business expansion and optimisation specialist at Phatsema Mining – a 100% black-owned business specialising in dust suppression, haul and load solutions, steel services, yellow machinery rentals, and the prevention of spontaneous combustion – concurs. He says, “Suppliers must constantly innovate withmore sustainable, water-efficient technologies and chemical additives, while also addressing concerns around runoff and environmental impact. Phatsema Mining offers solutions at highly competitive rates negotiable to suit site-specific budget constraints like biodegradable, and non-toxic polymer-based binders that dramatically reduce water consumption, labour demands and related operational expenditure. These advanced formulations incorporate high-performance surfactants and lignin derivatives, engineered to effectively bind dust particles, even in challenging conditions such as rainfall or extreme environments.”

He adds, “Mines are subject to increasingly stringent environmental regulations relating to air quality and dust emissions. Suppliers must therefore ensure that their dust suppression solutions meet or exceed these evolving standards, often varying across regions, borders and jurisdictions. Each mining operation also presents unique environmental and operational conditions such as climate, ore type, haul road design, and traffic volumes. This requires highly tailored solutions and continued developing of effective, site- specific programmes, while maintaining cost-efficiency – which is a constant challenge.

“Dust control must also be implemented without disrupting production. Solutions should be integrated seamlessly into mine operations and equipment cycles to avoid downtime, which can be costly. Mining companies often operate under tight budgets, especially during commodity downturns. Suppliers are required to demonstrate the long-term cost-effectiveness and return on investment (ROI) of their solutions, balancing performance with affordability.

“Ensuring that dust suppression products are safe for workers and do not introduce additional health hazards is also critical. Suppliers must invest in the development and certification of non-toxic, user- safe materials and application methods.

“There’s increasing demand for dust suppression systems that integrate with site-wide monitoring platforms, and technology integration and data monitoring is now required as mines become more digitised. Suppliers must develop smart systems that provide real-time data and analytics for improved decision-making and compliance reporting.”

 

Adaptability

Pretorius maintains that constant adaptability, technical expertise and a deep understanding of each commodity’s unique characteristics and challenges are required. “We recognise that each mining operation, whether in coal, gold, platinum, iron ore or industrial minerals, has its own set of operational demands, safety protocols, environmental regulations and processing requirements.”

To ensure efficiency and consistency across these diverse parameters, Phatsema Mining suggests implementing strategies like:

• Tailored operational plans – developing site-specific operational plans that align with the geological, geotechnical, and metallurgical conditions of each operation. This ensures optimal recovery rates, resource utilisation and cost-effectiveness.
• Technology and innovation – leveraging advanced technologies, such as process automation to enhance productivity and to streamline processes across all operational types.
• Sustainability and compliance – maintaining strict adherence to local and international environmental and safety regulations and adjusting supplied operational practices to the specific risks and compliance requirements of each mining operation.
• Collaborative engagement – working closely with mine owners, suppliers and communities to ensure that supplied operational models are not only commercially viable but also socially and environmentally responsible.

Dust remains a persistent challenge in mining operations, affecting both safety and efficiency. It can endanger the lives of workers, hamper operational efficiency, reduce overall productivity and increase maintenance costs for the mining fleet. Moreover, prolonged exposure to dust poses serious occupational health risks to employees and can impact the well-being of surrounding communities, raising environmental and social concerns. Agility and collaboration between suppliers, mines and communities is key to constantly improving the technology and processes needed to manage this challenge in the mining industry, and to ensure a sustainable environment and industry for all.

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