Introducing GelSAP™ Fine-Powder Road Dust Suppressant: From Lab Concept to Field Success

Dust on unpaved haul roads poses serious safety, environmental, and equipment-wear challenges across mining, construction, and bulk-handling operations. To tackle these issues head-on, our R&D team at GelSAP™ has engineered a next-generation solid dust suppressant—GelSAP™ Fine-Powder Dust Suppressant—that dissolves instantly in water, creating a uniformly low-viscosity spray solution. Here’s an inside look at our design process, standout product features, and real-world customer results.

1. R&D & Design Thinking

1. Field-Driven Insights

   • Operator Feedback: Early trials with granular GelSAP™ formulations revealed bridging and nozzle-clogging issues.

   • Equipment Constraints: Spray systems require consistent flow and minimal wear on pumps and hoses.

2. Particle Engineering

   • Fine-Powder Transition: We milled GelSAP™ into a uniform sub–150 µm powder, achieving consistent bulk density (0.58–0.75 g/cm³) for smooth feeding through automated dosing lines.

   • Optimized Cross-Linking: Adjusting cross-link density boosted water-uptake speed (≤ 13 s in 0.9% NaCl) while preserving high absorption capacity (≥ 40 g/g).

3. Solution Stability

   • pH Control (5.8–6.3): Ensures compatibility with steel tanks and spray components, minimizing corrosion risk.

   • Low Residual Monomer (≤ 350 ppm): Meets stringent environmental and health regulations.

2. GelSAP™ Product Highlights

3. Customer Case Studies with GelSAP™

A. Surface Mine – Nevada, USA

• Challenge: Severe dust plumes causing visibility issues and regulatory citations.

• Application: 2 t/month of GelSAP™ fine-powder suppressant via water-truck spray bars.

• Results:

  • 50% reduction in airborne particulate levels

  • 35% fewer shutdowns for road watering

  • Noticeable drop in haul-truck maintenance costs

B. Port Terminal – Santos, Brazil

• Challenge: Stockpile transfer roads kicking up dust that drifted into neighboring communities.

• Application: Automated spray booms using a 1 : 1,000 GelSAP™-to-water ratio.

• Results:

  • Zero community dust complaints in first quarter

  • 40% less freshwater usage vs. plain-water sprays

  • Improved worker morale and perception of site safety

4. Why Choose GelSAP™?

• Plug-and-Play: Integrates seamlessly with existing spray or misting systems—no retrofits required.

• Cost-Effective: High absorption means less chemical per kilometer treated.

• Sustainable: Reduces water consumption and minimizes environmental footprint.

• Dedicated Support: On-site commissioning and technical troubleshooting by our GelSAP™ application engineers.

5. Get Started with GelSAP™

1. Sample Kit: Request a free 5 kg trial pack of GelSAP™ Fine-Powder Dust Suppressant.

2. Customized Quote: Share your annual consumption and current supplier volume to unlock the best pricing.

3. Technical Partnership: Our team will work side-by-side with your operations crew for optimal spray setup.