CDC's dust suppression systems for continuous miners lead the field
Dust Buster News

For over 20 years Colliery Dust Control (CDC) has been a pioneer in the development of dust control systems used to improve working conditions and safety in underground collieries in South Africa.

Many of the dust suppression systems currently in use in underground collieries were developed by the company in conjunction with mine engineers at the mines.

Springs-based CDC is the largest supplier in the country of dust suppression systems for continuous miners. "We have supplied about 70 per cent of the dust suppression systems for the more than 280 continuous miners currently in operation in South Africa," says managing director Doug Hutson.

Since 1996 the company has consolidated its position as the leading supplier in its field, including the development and refinement of a three-fold integrated system comprising the unique CDC wet-fan scrubber box, water-powered air movers and a spray fan system operating in complementary fashion to achieve maximum dust suppression efficiency.

Backed up by sound product support and maintenance, together with the implementation by collieries of optimal mine ventilation and mining practices, the CDC integrated system consistently performs well within the limit of 5 mg/cu m as laid down by the Department of Mineral & Energy Affairs. The company was the first supplier to meet this requirement.

CDC has also greatly broadened its product range to encompass the full spectrum of dust suppression equipment and accessories, as well as providing round-the-clock service backup and a service exchange scheme to ensure that customers maintain maximum productivity and incur minimum downtime. In addition, it provides a service contract option whereby it takes full responsibility for service, maintenance and repair of the dust suppression systems.

"Several collieries that have taken advantage of this option have found it greatly to their benefit and we are encouraging others to go the same route because of the marked productivity improvements and savings that result from it," says CDC’s general manager Bob Johnstone.

CDC has an ongoing programme of improving the efficiency of operation and cost effectiveness of all the systems and equipment it supplies and services.

The company has consistently boosted its turnover and profits year-by-year since its change of ownership and management and relocation to Springs in 1996, resulting in its widespread recognition as the undisputed leader in the local market for dust suppression equipment for continuous miners.

"In the past four years we have transformed ourselves into a highly efficient and successful operation and are now fully justified in our claim of offering a one-stop dust suppression service to the industry," said Doug Hutson.

"We have ploughed all our profits back into the company to build up our infrastructure and systems to enable us to provide a comprehensive and complete range of equipment and services to customers to meet all their requirements."

During this period of expansion and consolidation the company has replaced most of its capital equipment, including its transport fleet. Staffing has been strengthened, with customer support staff in particular being expanded to enhance backup services.

Stock levels have been increased sixfold, resulting in greatly improved deliveries and elimination of back-orders. The company’s accounting package has been upgraded to ensure faster and more efficient processing of customers’ orders and stock renewals.

The CDC wet fan scrubber box – CDC’s core product – incorporates a high efficiency fan, a water-cooled low inertia motor, compact size, low power requirements, low water requirements and low noise levels. It has been developed in accordance with the industry’s requirements for high production rates and the high dust loads generated in South African coal mines, while requiring a minimum of maintenance.

The range of standard wet-fan scrubber box models has been increased from one to five, ranging in capacity from 4 cu m/sec to 17 cu m/sec, which have been produced in 18 different designs to date, including a curved side-outlet box specially designed for low seam continuous miners.

CDC has also introduced a number of improvements to the already well-established and widely used spray fan system, having enhanced the nozzle design, developed a robust reverse flush spray block and improved the spray block layout.

New products have been introduced, among them centrifugal pumps and Monitech monitoring equipment, comprising a water pressure and flow monitor, an air speed monitor and a methane detection monitor.

A new larger range of automatic reverse pulse water filters incorporating improved designs has also been introduced, while the pump shop devoted mainly to the D35 booster pumps supplied and serviced by the company has been revamped and expanded.

"But today our business is based more on supplying parts and service exchange units and providing on-going backup services than on selling new systems. With booster pumps, for example, we service five times as many units every month as we sell," Hutson points out.

"One of our greatest strengths is that we are a service-orientated company. Our turnover depends as much on good service as on offering a top quality and competitively priced product."