Manufacturing of a DustMASTER 40 TPH Series II Fly Ash Mixer for the Electric Utility Industry

DustMASTER® Enviro Systems has been a leader in dust control mixer systems from our home base in Pewaukee, Wisconsin since 1984. We were contracted to take on a project in the electric utility industry to determine if a DustMASTER system could successfully process water with PRB fly ash to achieve a dust-free product for landfill disposal. Using PRB fly ash from the economizer, we tested our DustMASTER 20 TPH machine for this capability in our test facility. All components of our mixer machine were engaged, including the Turbin style pan mixer with a hydraulically operated discharge door, metered water system and control, and a programmable controller with 100% manual override and load cell readout. We manually tested this material in our test facility, monitoring and recording the moisture percentage added by weight. When the whole process was complete, the final product was dust free, with 8% water and a 60-second cycle. The ball material and all fines were wetted through, and the fly ash was acceptable for transportation and landfill disposal.

This process exemplifies the effectiveness of our mixing equipment, as PRB fly ash is a very difficult material to mix properly with low moisture. Unlike our competitors, our mixer can de-dust this material with low moisture. We completed this test with documented results in one week for our client in the Upper Midwest. To learn more about this project, please see the table below or contact us directly.

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Highlights of the PRB Fly Ash Dust Control Mixer Project:

Project Scope
Test was conducted to determine if a DustMASTER system could successfully process water with the PRB fly ash to achieve a dust-free product for landfill disposal.
Material Tested
Fly ash from the economizer
Product Description
This product will condition PRB fly ash with water from an electrical utility.
PRB Dust Control Capabilities Applied/Processes
Primary:
Conducted manual testing of material in our test facility.
Overall Part Dimensions
Mixer test skid is: 7'-4" x 10'-0" x 8'-0" tall
Components
Turbin style pan mixer with a hydraulically operated discharge door
Metered water system and control
Programmable controller with 100% manual override and load cell readout
In Process Testing/Inspection Performed
Moisture percentage addition by weight. Results of tests monitored and recorded.
Industry for Use
Electric Utility Industry
Delivery/Turnaround Time
One (1) week for testing and documented results.
Delivery Location
Upper Midwest
Standards Met
Customer Specifications
Product Name
DustMASTER 40 TPH Series II
Project Outcome
Final product was dust free, with 8% water and a 60-second cycle. The ball material and all fines were wetted through. The fly ash was acceptable for transportation and landfill disposal.

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