Comprehensive Dust Suppression Solutions for Mining Operations

In today’s mining environment, effective dust control is non-negotiable. Gelsap™ has been at the forefront of mining dust suppression for over a decade, delivering innovative, reliable, and eco-friendly solutions that protect both people and the planet. Here’s how our multi-layered approach ensures your operation stays clean, compliant, and productive—and a real-world success story to illustrate the impact.

1. Advanced Water-Based Suppression

• High-Pressure Misting Systems

  • Precision-engineered nozzles produce ultrafine droplets (10–20 μm) that collide with respirable dust and rapidly settle it to the ground.

  • Modular frames and solar-powered pump options make deployment turnkey—even in remote open-pit sites.

  • Typical dust reduction: 85–95% on haul roads and crusher discharge points.

• Targeted Water-Injection Drilling

  • Integrates seamlessly with rotary and percussive drills.

  • On-demand water metering cuts consumption by up to 40% compared to continuous spray.

  • Proven to reduce airborne dust at heading faces by up to 60%, improving underground visibility and worker safety.

2. Innovative Chemical & Foam Technologies

• Surfactant-Enhanced Dry Fog

  • Generates sub-10 μm droplets that remain airborne longer, maximizing collision with ultrafine silica dust.

  • Up to 99% reduction in quartz respirable fraction at transfer points.

  • Low-volume application (0.5 L/min) conserves scarce water resources.

• Eco-Friendly Polymer Palliatives (Gelsap™ Seal)

  • Proprietary blends of lignosulfonates and magnesium chloride form a flexible crust on surfaces.

  • Lasts 4–8 weeks per treatment, depending on traffic and weather.

  • Biodegradable, non-corrosive, and compatible with reclaimed water.

3. Robust Engineering Controls

• Wind Fences & Barriers

  • Custom-sized geotextile fences installed around stockpiles and waste dumps.

  • Typical wind speed reduction: 30–50% downwind of barrier, slashing fugitive emissions.

• Enclosures & Local Exhaust Ventilation

  • Purpose-built shrouds around crushers, screens, and conveyor belts.

  • In-line high-capacity fans capture >90% of dust at transfer points before escape.

4. Smart, Data-Driven Management

• Real-Time Dust Monitoring

  • Industrial-grade PM₂.₅ and PM₁₀ sensors networked via LoRaWAN.

  • Dashboard alerts trigger automated misting or foam activation when thresholds are exceeded.

• Predictive Analytics & Automation

  • Machine-learning models ingest wind speed, humidity, throughput volume, and historical dust data.

  • Automatically schedule pre-emptive treatments ahead of high-risk operations or weather events.

5. Proven Performance & Support

• Industry Leadership

  • Deployed at 200+ sites across North America, Australia, and Africa.

  • Average client ROI within 6 months through reduced downtime, regulatory fines, and water savings.

• Turnkey Service

  • Comprehensive site audit and dust-mapping report.

  • Custom design, installation, operator training, and 24/7 remote support.

  • Seasonal maintenance plans ensure no-break performance, even in extreme climates.

Customer Case Study: Iron Ridge Mine, Western Australia

Challenge:
Iron Ridge Mine, an open-cut iron ore operation handling 25 Mtpa, struggled with excessive dust during the dry season (July–October), leading to frequent visibility shutdowns and community complaints.

Solution:

• Installed Gelsap™ High-Pressure Misting at three primary crusher transfer points.

• Applied RoadSeal polymer palliative on 12 km of haul road, re-treating every six weeks.

• Deployed IoT sensors at four downwind receptors and integrated them with our cloud-based control platform.

Results (First 6 Months):

• Dust Concentrations (PM₁₀): Dropped by 92% on average at key receptors.

• Operational Uptime: Increased by 8%, avoiding over 120 hours of shutdowns.

• Community Complaints: Reduced by 75% compared to the previous dry season.

• Water Usage: Decreased by 35% through optimized spray scheduling and palliative longevity.

“Partnering with Gelsap™ transformed our dust management. Their technology and support helped us maintain continuous operation and strengthen community relations.”
— Operations Manager, Iron Ridge Mine

Choose Gelsap™ to safeguard your workforce, exceed stringent environmental regulations, and optimize operational efficiency.
Contact us today for a free site assessment and discover why Gelsap™ is the gold standard in mining dust suppression.