Issue link: http://read.dmtmag.com/i/75471
OPERATIONS ILLUSTRATED T Voices of Experience Kirk Fuller with regulations coming down the line, says Plant Manager Kirk Fuller. "Lehigh Hanson engages proactively with the National Stone, Sand & Gravel Association and the regulatory agencies, exchanging meaningful input. But the bottom line is that, from a regulations standpoint, we know we have to be in compliance. From a company standpoint, we're being good neighbors. It's part of being in the community, " he says. "We listen to what's going on in the political and regulatory arena, but we also listen to what our neighbors are saying. " Fugitive emissions are the visible emis- sions that cause neighbor concerns. To combat them, the Bridgeport plant has put numerous measures into place. The company has an elaborate dust suppression system in place at all stages of the process- ing plant. A paved concrete road runs from the entrance to the loadout portion of the plant, so that most of the customer trucks never leave a paved surface. "Not many facilities do this," Fuller says. Additionally, this facility fractionates its material, blending it just prior to loadout, rather than blending and stockpiling. The practice reduces handling of the material, which reduces the amount of fugitive dust. "By conveying the (blended) material to the customers, versus them coming to us within the plant, we create fewer fugitive emissions, and also fewer engine emissions," Fuller says. "We have an extensive reliability main- tenance program that includes a high level of inspections," Fuller says. "We monitor fuel burn, make sure we understand each machine's oil/lube program fully, and replace parts when needed — before they break. a machine is running within its operating parameters and translates to lower engine emissions. AGGREGATES MANAGER ▼ Brian Yureskes he Lehigh Hanson Bridgeport Quarry works to exceed current emis- sions regulations and also stay in tune to this is reduced levels of carbon emissions. Hybrid engine cars have gained popularity over the past decade for their fuel efficiency and reduced carbon footprint, with heavy equipment expected to follow suit. In the past several years, two equip- W ment manufacturers introduced engine models to North America that qualified for funding through the California Air Resources Board's (CARB) Hybrid Off- Road Equipment Pilot Project. One of these manufacturers, Komatsu America, recently introduced a hybrid excavator that illustrates how hybrid technology can be put to work in mining. The HB215LC-1 excavator is powered by a system that includes an electric swing motor, power generator motor, capacitor, and a 139-horsepower diesel engine. The company developed the hybrid system to work on the principle of swing energy regeneration and energy storage using a capacitor, rather than a battery (as used by a hybrid car). As the excavator swings, it is the swing- braking phase that produces kinetic energy, which is converted to electricity, sent through an inverter, and captured by the capacitor. The captured energy is then used to assist with upper structure rotation and/ or the engine, as commanded by the hybrid controller, when the excavator accelerates under workload conditions. "Because of the assistance provided " Efficient fuel burn, he says, indicates by the hybrid system, the hybrid excava- tor achieves the same performance as a conventional machine, even with a smaller engine and less horsepower. It helps create lower emissions by reducing the amount of fuel consumed during typical operation," says Brian Yureskes, product manager, ex- cavators, for Komatsu. He explains that fuel savings can be as great as 25 to 40 percent when compared to a conventional machine. ▼ Derek Roberts ith rising fuel prices, it makes good sense to reduce energy con- sumption. A byproduct benefit A " t the Lacey's Spring Quarry, Rogers Group has installed the most advanced emission-control technology available to minimize fugitive emissions. The company also ensures the system — which includes filters, hoses, and spray nozzles — is well maintained so that it does not become plugged. "One thing we've learned over the years is that more water does not necessarily mean less dust," says Derek Roberts, vice president of Rogers Group's Alabama operations. "The spray nozzles today do more with atomizing of water droplets, which provides better coverage with less water. The Rogers Group's culture is apparent in its work to reduce greenhouse gas emis- sions. The following series of initiatives has been implemented, Roberts says. storage fuel tanks, providing equip- ment with cleaner fuel to ensure maximum yield during combustion; scopic high-efficiency filtration bank at the fueling stations; additive, which reduces carbon buildup, increases stability, and increases lubricity; and devices that shut down equipment idling for more than five minutes. Maintenance best practices at Lacey's Spring improve engine combustions, too. Maintaining equipment to all OEM recommendations for particulate matter levels ensures the engines run at peak performance and minimizes the effects of soot and low viscosity. "We also per- form annual exhaust-gas testing, which provides critical information of the emis- sions from our engines," Roberts says. "We can take corrective actions to adjust the air:fuel ratio, or replace sensors and injectors. " ▼