published regulatory change for mining facilities’ air quality related to respirable crystalline silica in April 2024, with changes taking effect June 17, 2024. Here, we’ll answer your most pressing questions to help you meet the MSHA respirable crystalline silica standard in your facility.

Navigate the proposed respirable crystalline silica standard with a proven partner. Talk with an ��һ��ݶ�project engineer today. It’s the first step you can take toward meeting the proposed MSHA Respirable Crystalline Silica Standard.

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��һ��ݶ�– 100,000 CFM Dust Collector Assembly

The Project
Foundry Application to Mitigate Dust Exposure
6 Months Before: Design and Engineering
4 Months Before: Fabrication
1 Week Before: 3-Person Crew Site Prep

The Crew
60 Years Crew Experience
Six-Person Installation Team

The Installation
Baghouse Assembly Built Up from Hopper
Custom Structural Steel and Staircase
Pre-Assembled Catwalk and Walk-In Plenum Access

Final Product
65-Foot Tall Assembly
90-Foot Tall Stack
1000+ Filters Installed
Meets EPA Standards

��һ��ݶ�– Metal Fabrication • Industrial Ventilation

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If you are interested in how ��һ��ݶ�can help your business, contact us.

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Mining Ventilation Systems and Material Handling Equipment

In the mining industry, ��һ��ݶ�provides industrial ventilation systems which include exhaust systems as well as make up air systems. In addition to ventilation systems ��һ��ݶ�provides material handling equipment which include belt conveyors, bucket elevators as well as all the transfer chutes between all of the pieces of equipment. It is an advantage for IVI’s customers to use us to do both the industrial ventilation systems as well as the material handling equipment.

It is critical how both of those areas react with each other and interact. Silica exposure is a great concern in the mining industry. Proper industrial ventilation systems as well as material handling systems can greatly reduce the exposure level. With the combination of dust collection systems as well as make up air systems, silica levels can be reduced to a point where personnel can operate within facilities.

Knowledge and Experience with Mining Ventilation Systems

What sets ��һ��ݶ�apart with industrial ventilation in the mining industry is we have knowledge and exposure to material handling equipment design, chute design, as well as the ventilation package. So even if you have an existing system, we can come in and make improvements to improve the dust collection as well as reduce silica exposure.

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Why Conduct an Industrial Ventilation Analysis

In an industrial ventilation analysis, we conduct an air quality survey by taking air readings of the ventilation system, as well as evaluate the dust collector, fans and all system components. From there, we develop a baseline rating of the entire system—a useful tool in determining what may need to be done, or not done, with your dust collection system. If you’re unsure whether an engineering study is right for you, here are the primary reasons to request an analysis.

Reason #1: Adding equipment

When adding equipment, you may need to expand the ventilation system. The best way forward is to start by evaluating the current system and its capacity. With that knowledge, you’ll then know whether your current system can handle more volume and how that may affect the collection volume from other equipment.

Also, adding equipment doesn’t automatically mean you need to add to your ventilation system. A ventilation analysis may show that you already have excess capacity. We may also be able to redesign the system to keep you from rerouting ductwork or buying a new dust collector.

Reason #2: Changing a manufacturing process

A manufacturing process change may mean greater particulate volume being directed to an area not equipped to handle the excess. If gone unchecked, particulate can build up in the ductwork, adding weight that can cause the duct to fail. And if the duct isn’t built to carry extra weight, facility damage and employee injuries may occur.

Reason #3: Becoming more energy efficient

Many companies are looking to be more environmentally conscious by using less energy. Even though an older dust collection system continues to do the job well, it may be costing more to run. Older fans, for example, can be a culprit. An engineering survey would show whether you could save energy and money with newer, more efficient equipment, depending upon your system design and layout.

Reason #4: Becoming silica standard-compliant

The silica standard is a high bar. If silica is part of your manufacturing process and you are having difficulty meeting the standard, there are a couple of things you should do. First, hire an industrial hygienist who will analyze your facility for silica risk. For example, the hygienist will take samples for every employee in every area of your plant for every shift. Once you have that information, we can then conduct an engineering study to review your entire system and determine how best to capture the silica.

What to Expect When Your Industrial Ventilation Analysis is Complete

Once we take the air quality survey readings and inspect your system, we develop a comprehensive written report of our findings. You’ll receive data on your equipment and ventilation system with indication of whether it’s collecting particulate effectively and where improvements, if any, are needed. We then:

• Request a follow-up meeting to discuss areas that need improvement
• Develop a conceptual design
• Develop a proposal that includes our costs based on our design
• Once agreed upon, implement the solutions

Getting an engineering study done is much like going to the doctor—it helps ensure everything is operating the way it should. If you believe an industrial ventilation analysis would benefit your company, contact us to schedule a survey.

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Silica Dust Collection: Meet the Standard with a Makeup Air System

Drying, screening and transferring silica-laden materials is a significant concern in mining operations. With proper dust collection design, exposure limits can be reduced to meet the .

The best silica dust collection is about more than removing particulates. It also addresses the air that is taken away within the process. When a dust collector is installed in a mining facility, it naturally draws air out of the building. Because that air needs to be replaced, air is drawn in, usually through doors and cracks. When a high-velocity draft comes into the building and mixes with sand and particulates left on floors or equipment, it can create high silica levels and put employee health at risk.

The answer is a makeup air system. Designed as part of a mine ventilation system, makeup air systems bring fresh, clean air into the plant. These systems play a key role in reducing silica levels, allowing personnel to work safely inside. Despite their benefit, they are often overlooked in dust collection design, so many plants lack them.

Material Handling Equipment and Dust Collection, A Perfect Pair

Belt conveyors, bucket elevators and transfer chutes are all critical components in mining operations. And while many may think material handling equipment works independently of dust collection systems, that’s simply not true. Many times, dust collection design intersects with material handling design. The interaction between the two is critical and can reduce the amount of good material being carried away within the dust collector.

IVI: An Experienced, Certified Mine Ventilation Team

Perhaps one of the greatest benefits of working with ��һ��ݶ�on mine ventilation systems is our depth and breadth of expertise.

• As the (MSHA) enforced the silica standard, we’ve been successful in designing new systems or retrofitting current systems to meet the rigorous standard. We do that with a combination of dust collection and makeup air systems.
• We excel at dust collection design as well as material handling fabrication. When we are involved in both during a project, we can successfully reduce the amount of product being carried away. Installing low-velocity take-off points and ductwork systems keeps product in the process.
• Because MSHA training and certification is required to work at a mining site, we have a wide range of certified employees—engineers, designers, and shop and field personnel—ready and available to service our mining customers.

Ask About Our Mine Ventilation System Expertise

Use our expertise to your advantage. When we combine our dust collector and makeup air system design with our material handling fabrication, we’re able to ensure your product doesn’t get carried away with unwanted particulates. Most importantly, ��һ��ݶ�dust collection systems help keep your employees safe. Contact us to get started.

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Industrial Dust Collection System Design

When appropriate, we test designs before fabrication begins. While computational fluid dynamics modeling tells us part of the story, our R&D lab makes the invisible visible. In other words, it gives us real-world validation of our dust collection design and CFD modeling. We’ve used the test lab to help us:

• Determine air flow velocity to qualify the efficiency of a dust collector design
• Troubleshoot potential problems before a dust collector is installed as part of a production process
• Test fabricated hoods before they ship

That gives peace of mind—for us and our customers.

IVI’s R&D Test Lab: A Response to Paper and Tissue Industry Needs

We built our in-house test lab when working on a pulp, paper and tissue dust collection design. The paper and tissue industry faces rigorous schedules. Demand for paper and tissue products is high. Downtime is a nemesis. To keep downtime to a minimum, we developed the lab to set up and test all the possible scenarios the system might face in the field. The result: An industrial dust collection system design that worked the first time, allowing our paper and tissue industry customer to keep product moving.

Case Study: How We Use Our Test Lab in Designing a Dust Collection System

Our test lab is set up with a push-pull system. One nozzle pushes air and particulate to another nozzle that pulls the particulate into a hopper. These nozzles are installed on the floor, which is covered in 12 by 12 tiles that help us graph data points. The data is compared to our software designs.

We use customers’ actual waste particulate for testing dust collection or smoke bombs paired with high-intensity light for testing fume collection. By covering the entire floor in dust or emitting fumes, we can see clearly where the system works efficiently and where it doesn’t.

As the nozzles capture particulate or smoke, we take air velocity readings. We’ve also installed a small-scale baghouse that helps us measure air flow of specific particulate. Our goal: Use the least amount of air needed to disperse the particulate to increase efficiency and cut costs.

Contact us for Dust Collection Design

Our engineering and design team is known for flexing its creative muscles to meet our customers’ goals. Our R&D test lab is an extension of our innovation, showing us the parameters we can push when designing a dust collection system.

If you need help with industrial dust collection design for dust or fumes, contact us to see how we can help.

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Types of industrial baghouse dust collectors:

• Pulse jet baghouse dust collector
• Reverse air baghouse dust collector
• Shaker baghouse dust collector

After learning about your facility, regulatory requirements and particulate matter you need to filter, the ��һ��ݶ�team taps decades of experience to identify the industrial baghouse dust collector that’s right for you. Here are the types of baghouses we consider:

Pulse Jet Baghouse Dust Collector

In pulse jet baghouse dust collector operation, puffs of pressurized air “pulse” incoming air through the filters for cleaning. Pulse jet dust collectors are the most common type of baghouse dust collector used in industry today.

Reverse Air Baghouse Dust Collector

Industrial reverse air baghouse dust collectors are typically used in wood dust applications with larger chips or when particulate matter has low densities and/or large aspect ratios. Reverse air baghouse operation involves a low-pressure reversed flow to backflush the air through the filter bags. Once backflushed, the filtered air is released back into the environment for recirculation.

Shaker Baghouse Dust Collector

Industrial shaker dust collectors are occasionally used for areas and facilities where it’s not practical to have compressed air. Mechanical shaker baghouses remove particles by mechanically shaking the filter bags. This causes the heaviest pieces to fall into a hopper while the smaller pieces are stuck against the inside or outside of the bags, depending on the design.

Shaker baghouse dust collectors are nearly obsolete and have limited applications due to required regulatory efficiencies and necessary maintenance.

Custom Design Baghouse Dust Collector Capabilities

Whether your facility requires a reverse air or pulse jet baghouse dust collector, ��һ��ݶ�has a custom design-build department which allows us to conduct both engineering and custom design in-house for any type of industrial baghouse dust collector. We can design a unique baghouse to fit your needs according to regulatory emission rates, particle type, explosion protection guidelines, the size and type of your facility and air-to-cloth ratios.

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Why ��һ��ݶ�Excels at Plan and Spec Projects

��һ��ݶ�excels at plan and spec projects because we have the experience of engineering and designing projects as a design-build contractor. When we’re awarded a project that is plan and spec our field crews, our project managers bring their experience on our own design-build projects to that project.

Industrial Ventilation Experience Across Industries

IVI’s worked on a number of different projects in a number of different industries. From foundries, to the pulp and paper, automotive, mining. We’ve even done some commercial HVAC work as part of bigger projects so there’s not many plan and spec projects we haven’t been a part of.

Making Industrial Ventilation Installation Easier

On plan and spec fabrication, ��һ��ݶ�with their experience on the field install side, fabricates to the knowledge that that field crew needs a quality product to install. Something that has been reviewed through our quality process to make sure ninety-degree elbows are 90 degrees, and that everything fits and is aligned properly for an easier install. Making sure that the fabrication matches the prints.

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Industrial Ventilation Design to Find Solutions

A design-engineered solution is a project that does not have a defined scope. It can be as small as a duct work problem that has a moisture issue and is plugging to as large as a greenfield construction site that needs a completely designed and engineered ventilation system.

Leaders in Industrial Ventilation Design

What really sets ��һ��ݶ�apart in the industry is our full staff of engineers ranging from mechanical, environmental and civil engineers. Having this whole team of engineers in-house allows our customer to have one point of contact for their engineer solutions. Not only does ��һ��ݶ�have a full line of engineers on staff, we also have eight full-time designers that bring the engineered solutions to life.

During many plan and spec projects IVI’s engineering design services can aid the customer with unforeseen delays and obstructions within the project. ��һ��ݶ�can react quickly and come back with a engineered solution to correct the problem to keep the project on track.

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In this video, ��һ��ݶ�Project Engineer Doug Schauer discusses the ingredients that lead to a combustible dust explosion, industries most at risk for dust explosions and how to protect your facility. See how ��һ��ݶ�can help through its design, build and install industrial ventilation services.

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What Causes Combustible Dust Explosions?

Combustible dust are fine particulates usually created in the manufacturing environment that present an explosion hazard under certain conditions when this dust is suspended in the air. Dust explosions can be fatal they can cause equipment damage they can even destroy your facility.

There’s five ingredients for a dust explosion.

• The dust itself which has to be combustible.
• The dust needs to be suspended in the air or it needs to be like a cloud of dust.
• The dust needs to be contained, and
• There also needs to be oxygen.
• Then of course the ignition source.

It’s called the dust explosion pentagon.

There’s a lot of dust out there and people don’t realize how many dust are actually combustible or explosive. It could be agricultural it could be carbon based, metallic dusts, chemical dust and even plastic dust.

Combustible Dust Explosion Protection

The best way to protect your facility from a dust explosion is if you do have a dust collector and if you’re installing it install your dust collector outside that way if there is an explosion it will be away from employees and your facility. One thing you can do immediately is just get to get it on your PM program. A lot of the facilities have a preventative maintenance program so you can as you’re looking at this equipment checking out the equipment you can check for dust that’s maybe accumulating, you can check for dust that’s puffing out of the equipment.

How ��һ��ݶ�Can Help Prevent Combustible Dust Explosions

We can help you. We can we can do some tests on your dust collection system. We can take air flow readings, we can balance your system so you get the proper collection. ��һ��ݶ�can also help you out with a hazard assessment of your of your facility just to see what to see if you do have dust that are combustible. We can look at your equipment to make sure it’s operating properly, things like that. We can also take a sample of your dust and test it to see how explosive it is.

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