Dust suppression method and system

Abstract

The present invention relates to a dust suppression system for controlling dust from rail ballast materials being transported in open wagons on a rail track, comprising: a gantry positioned above and spanning a section of the rail track, the gantry comprising a platform supported by stanchions, wherein the platform has an elongate opening configured orthogonally to the rail track; a spray head positioned within the elongate opening of the platform, the spray head comprising spray bars with nozzles configured to discharge water droplets onto the rail ballast materials being transported in open wagons; and a control system comprising proximity sensors to detect the presence of an open wagon and activate the spray head.

Description

[0001] DUST SUPPRESSION METHOD AND SYSTEM

[0002] TECHNICAL FIELD OF THE INVENTION

[0003] The present invention relates to a dust suppression method and system. More particularly, the present invention relates to a method and system for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network.

[0004] BACKGROUND

[0005] Track or rail ballast is the aggregate material which forms the part of the track bed upon which sleepers are laid. It is packed between, below, and around the sleepers, and is used to bear the compression load of the sleeper, rails and rolling stock to facilitate drainage, and otherwise maintain the overall integrity of the track structure.

[0006] A variety of aggregate materials are known to be used as rail ballast, including crushed stone and gravel. In the United Kingdom, rail ballast aggregate is typically 30mm to 50mm in size, and is typically granite as its strength provides natural durability, although other types of aggregate can be used.

[0007] Rail ballast only has a limited lifespan. Over time, ballast wears down and becomes rounded. The pieces of ballast fit together less easily, reducing effectiveness. Granite fines are also created by attrition which tend to stick together when combined with water, and causing the ballast to behave like a solid mass. The worn ballast no longer has the flexibility to constrain the track as it moves under traffic, and track drainage can be impacted.

[0008] This is a major problem for the rail industry as over time this worn ballast has to be replaced with new angular ballast.

[0009] Vast quantities of ballast are therefore required for new network installations and remedial replacements. There are significant health risks associated with working with rail ballast which have been recognised by the industry. Silica is a very common mineral found in sand and rocks, such as granite ballast. This silica dust is hazardous to health when inhaled. Workers who work with these materials are at potential risk of developing silicosis as a result of their exposure to silica. Silicosis is a preventable, but incurable, respiratory disease which can be caused by inhaling silica dust. If this dust is inhaled, small particles of it can become embedded into parts of the lung and which cannot be cleared by mucous or coughing.

[0010] Silica dust can be controlled by protecting workers health by wearing a respiratory mask. But these are not popular, and they all have one major drawback, and that is the uncomfortable build-up of heat and moisture that can often occur inside the respirator. As the wearer works harder, and / or wears the respirator for extended periods of time, the problem of heat and moisture build-up is exacerbated.

[0011] There is therefore need for a straightforward and effective means of suppressing dust when transporting and working with the very vast quantities of rail ballast that is needed for remedial repairs or replacement, or new installations.

[0012] Accordingly, an object of the present invention is to provide a dust suppression method and system for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network. This leads to a much-safer worksite environment. It is a further object of the present invention to provide a dust suppression method and system that utilises sprayed water droplets which attach themselves to the dust particles, making them heavier and less likely to become airborne. It is a further object of the present invention to provide a dust suppression method and system that utilises minimal natural resources, and requiring no surface agents or other contaminants. It is a further object of the present invention to provide a dust suppression method and system that can automatically wet the very vast quantities of ballast being transported to a worksite, for example, when leaving a siding or other section of track in an open wagon. In this way, no additional time, effort or process steps are needed for controlling the silica dust. It is a further object of the present invention to provide a dust suppression method and system that utilises rainwater capture and solar energy to ensure a reliable and uninterrupted power and water supply essential for sustaining dust suppression with minimal energy requirements and resource consumption. SUMMARY OF THE INVENTION

[0013] The present invention is described herein and in the claims.

[0014] According to the present invention there is provided a dust suppression system for controlling dust from rail ballast materials being transported in open wagons on a rail track, comprising: a gantry positioned above and spanning a section of the rail track, the gantry comprising a platform supported by stanchions, wherein the platform has an elongate opening configured orthogonally to the rail track; a spray head positioned within the elongate opening of the platform, the spray head comprising spray bars with nozzles configured to discharge water droplets onto the rail ballast materials being transported in open wagons; and a control system comprising proximity sensors to detect the presence of an open wagon and activate the spray head.

[0015] An advantage of the present invention is that the dust suppression system provides a straightforward and effective means of suppressing dust when transporting and working with the very vast quantities of rail ballast that is needed for remedial repairs or replacement, or new installations.

[0016] Preferably, the spray head comprising a pair of elongate spray bars configured in a spaced-apart arrangement, with a centrally-disposed connection pipe in fluid connection between the pair of spray bars.

[0017] Further preferably, the nozzles on the spray bars are positioned on the underside thereof and configured to direct jets of water downwards onto the rail ballast materials.

[0018] In use, the spray head may be configured to cover at least the track gauge of the rail track to ensure effective coverage of the rail ballast materials in the open wagons.

[0019] Preferably, the control system includes solenoid valves controlled by the control system to activate the water spray nozzles upon detecting the presence of an open wagon. Further preferably, the spray head having a generally discorectangular shape with spaced-apart longitudinal spray arms and semicircular ends.

[0020] In use, the spray head may have a closed loop configuration to enhance water circulation and pressure, with a connector pipe supplying water to the centre of the spray head.

[0021] Preferably, the nozzles on the spray head are configured to deliver a discharge flow rate of water of between 60 and 70 litres per second.

[0022] Further preferably, the gantry includes anti-slip grating and safety handrails for operator safety.

[0023] In use, the system may comprise a water tank tower in fluid connection with the spray head via a supply pipe which maintains water pressure and levels.

[0024] Preferably, the system operates in manual, semi-automatic, and automatic modes, with the automatic mode activated by the detection of a locomotive passing the stanchion and a subsequent time delay.

[0025] Further preferably, the system further comprising means for capturing rainwater to supply water to the water tank tower of the system.

[0026] In use, the system may further comprise solar cells and batteries to provide electrical power to the system.

[0027] Preferably, the gantry includes structural components such as crossmembers, cross braces, and comer pieces.

[0028] Further preferably, the stanchions of the gantry are seated upon concrete structural bases and secured via bolted column connections.

[0029] In use, the gantry may further include a staircase leading to a ladder with a safety hoop for accessing the platform. Preferably, the water tank tower comprising an elongate cylindrical tank seated on a structural concrete slab.

[0030] Further preferably, the water tank tower includes stanchions, crossmembers, and cross braces.

[0031] In use, the water tank tower may include a ladder with a safety hoop for operator access.

[0032] Preferably, the water tank tower includes an anti-slip grating and safety handrail to ensure operator safety.

[0033] Also according to the present invention there is provided a method for controlling dust from rail ballast materials being transported in open wagons on a rail track, comprising: supplying water to a spray head from a water source, the spray head being positioned on a gantry above and configured to cover at least the track gauge of the rail track, the spray head comprising spray bars with nozzles configured to discharge water droplets onto rail ballast materials being transported in open wagons; detecting the presence of an open wagon beneath the gantry using proximity sensors; and activating the spray head and discharging water droplets from the spray head onto the rail ballast materials being transported in the open wagon.

[0034] It is believed that a dust suppression method and system in accordance with the present invention at least addresses the problems outlined above.

[0035] It will be obvious to those skilled in the art that variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.

[0036] BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will now be described by way of example only, and with reference to the accompanying drawings, in which: Figure 1 is an isometric view from one side and above of a system for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network in accordance with the present invention;

[0038] Figure 2 shows a isometric view from the opposite side and above of a system for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network in accordance with the present invention; and

[0039] Figure 3 illustrates a perspective view from the side and above of a section of the elevated platform, and shows a spray bar in accordance with a second embodiment of the invention which is capable of discharging a high volume of water and having a wide spray pattern.

[0040] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] The present invention has adopted the approach of providing a dust suppression method and system for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network. This leads to a much-safer worksite environment. Advantageously, the present invention provides a dust suppression method and system that utilises sprayed water droplets which attach themselves to the dust particles, making them heavier and less likely to become airborne. Further advantageously, the present invention also provides a dust suppression method and system that utilises minimal natural resources, and requiring no surface agents or other contaminants. Further advantageously, the present invention also provides a dust suppression method and system that can automatically wet the very vast quantities of ballast being transported to a worksite, for example, when leaving a siding or other section of track in an open wagon. In this way, no additional time, effort or process steps are needed for controlling the silica dust. Further advantageously, the present invention also provides a dust suppression method and system that utilises rainwater capture and solar energy to ensure a reliable and uninterrupted power and water supply essential for sustaining dust suppression with minimal energy requirements and resource consumption.

[0042] Referring now to the drawings, a dust suppression system 10 for controlling silica dust from rail ballast materials when being transported on open wagons on the rail network is illustrated in Figures 1 and 2. The dust suppression system 10 of the present invention comprises a gantry 12 which is situated above and spans a section of rail track 14. It is upon rail track 14 that various rail vehicles including, but not limited to, wagons, engineering trains, freight trains, machinery, passenger trains, plant, road-rail vehicles, trailers and trolleys can pass under the gantry 12. In the illustrative example shown in Figure 1, the train which is shown passing under the gantry 12 is a passenger train 16, although in use the dust suppression system 10 of the present invention is specifically configured to control silica dust from rail ballast materials when being transported on open wagons on the rail track 14, as will be described in further detail below.

[0043] The gantry 12 can vary in design, depending on the configuration of the surrounding terrain and rail network 14. In the embodiment shown in Figures 1 and 2, the gantry 12 comprises a number of generally vertical support members or stanchions 18 which support generally horizontal support members forming a horizontal platform 20. In a preferred embodiment, the stanchions 18 comprise universal column structural elements, and the generally horizontal support members 20 comprise universal beam structural elements.

[0044] The horizontal platform 20 has a rectangular shape when in plan view from above and configured having a pair of spaced-apart outer longitudinal members 22 situated between a pair of spaced-apart outer end members 24, such that the longitudinal members 22 are generally orthogonal to the rail track 14.

[0045] The skilled person will also appreciate that any size or geometrical configuration of horizontal platform 20 is entirely possible, including any number of circular and / or ellipsoid and / or rectangular and / or curved geometric shapes, including pentagonal, hexagonal, octagonal or any suitable polygonal shape when in plan view, and this is not intended to be limiting.

[0046] Towards the centre of the horizontal platform 20, a pair of spaced-apart inner longitudinal members 26 are situated between a pair of spaced-apart inner end members 28. For structural rigidity, a series of structural ribs 29 are also included that run between the outer and inner longitudinal members 22, 26. The inner longitudinal members 26 and inner end members 28 therefore form an elongate or slotted opening 30 towards the centre of the horizontal platform 20, as perhaps best shown in Figure 3.

[0047] A continuous path of anti-slip grating 32 is positioned completely surrounding the opening 30. The anti-slip grating 32 being such that an operative can safely stand on the platform 20.

[0048] To ensure worker safety, an outer hand rail 34 passes around the outer edges of the platform 20. Likewise, an inner hand rail 36 protects a worker from falling through the opening 30.

[0049] The stanchions 18 include various crossmembers 38 and cross braces 40 as well as corner pieces 42, as would be known to someone skilled in the art to provide a structurally sound gantry 12.

[0050] Each of the stanchions 18 can be seated upon a concrete structural base 44 and secured and to it via a bolted column connection 46. Again, depending upon the surrounding terrain a staircase 48 may be needed that leads to a vertical ladder 50 with a safety hoop 52.

[0051] As can be best seen from Figure 1, a worker or operative is able to traverse the staircase 48 and climb ladder 50 to safely access the horizontal platform 20 and walk upon grating 32.

[0052] At its core, the gantry 12 acts as a structure that can support a spray head 54 for discharging water droplets onto rail ballast materials being transported on open wagons on the rail track 14.

[0053] Again, as perhaps best shown in Figure 2, the elongate opening 30 is configured such that it is passes orthogonally across the track 14 when in a plan view from above. Configured in the same orientation as the opening 30 is the spray head 54 that in the embodiment shown in Figure 1 is elongate. The spray head is at least wider than the gauge of the track 14 it is positioned over, ensuring effective coverage. The embodiment of the spray head 54 shown in Figure 1 comprises a pair of elongate spray bars 56a, 56b that are configured in a spaced-apart arrangement. In fluid connection between the pair of spray bars 56a, 56b is a centrally-disposed connection pipe 58 which, in turn, is in fluid collection with a supply pipe 60 which is located at one side of gantry 12.

[0054] Although not visible in Figures 1 and 2, disposed along the length of each of the spray bars 56a, 56b at the underside thereof is a series of apertures or nozzles that, in use, can direct a continuous stream of water downwards onto the track 14 below. The skilled person will understand that when water pressure is applied, jets of water are discharged onto the rail ballast as it is transported in open wagons passing along track 14 underneath the spray bars 56a, 56b. It is the sprayed water droplets which attach themselves to the dust particles, making them heavier and less likely to become airborne, thereby suppressing or controlling dust.

[0055] In order to produce the necessary capacity and flow rate of water, a separate water tank tower 62 is necessary. This is the second structure of the dust suppression system 10 as illustrated in Figures 1 and 2. Again, in common with the gantry 12, the water tank tower 62 may take many forms. However in the preferred embodiment shown in Figures 1 and 2, the water tank tower 62 comprises an elongate cylindrical tank 64 that is seated on a structural concrete slab 66 as necessary for the building and safety regulations for the relevant country concerned.

[0056] The shape of the water tank tower 62 surrounding the water tank 64 is designed to be adaptable, allowing it to change depending on the specific requirements of each installation, and its terrain. This flexibility in design ensures that the access tower 62 can be customised to accommodate various site constraints and environmental conditions, enhancing its utility.

[0057] In order to regulate and maintain pressure and water levels throughout the system 10, a water towers 62 is used to store water and manage flow. Again, the water tank tower 62 includes structural components such as vertical stanchions 68, horizontal support members 70 and cross braces 72. Again, the stanchions 68 are seated and bolted to concrete supports 74 using bolted column connections 75. The top of the water tank tower 62 comprises anti-slip grating 76 which is surrounded by a safety hand rail 78, such that an operative can safely stand upon the water tank tower 62. Access to the water tank tower 62 is via ladder 80, which includes a safety loop 82. The water tank tower 62 therefore provides access points for maintenance personnel or operators to inspect and service the tank 62 and its pipework and valves, and other components.

[0058] The cylindrical water tank 64 is designed to store and distribute water efficiently. The cylindrical structure ensures uniform distribution of stress, providing stability and durability under varying environmental conditions. The design prioritises structural integrity to withstand environmental stresses while maintaining a consistent supply of water.

[0059] An inlet feed (not shown) is received at a control box 84 located at the base or lower section of the gantry 12. This inlet is connected to an external water supply, which could be a municipal water line, a well, or a natural water source. A non-return valve can be integrated into the inlet to prevent backflow, ensuring a consistent and uncontaminated water supply. This configuration ensures that the tower can continuously receive water without contamination, maintaining a reliable reservoir for use.

[0060] The water inlet supply is controlled via stop valves (not shown) that are selectively controlled within the control box 84 to supply the cylindrical tank 64 along bidirectional pipe 86.

[0061] The outlet pipe 86 is located at a lowest point within the cylindrical tank 64, ensuring a gravity-fed flow of water. The pipe 86 diameter is designed to handle large volumes of water, making it ideal for high-demand applications. A pressure-regulating valve may be installed at the outlet to maintain optimal water pressure, ensuring the efficient distribution of water. Also not shown within the control box 84 is a pump which is controllable to maintain and deliver water at a consistent rate and pressure drawn from the tank 64 along pipe 86 and pumped up supply pipe 60 to the spray head 54. The system 10 is designed to efficiently spray water onto rail vehicles located beneath the spray head 54 using proximity sensors 88 which can detect the presence of an open wagon. These sensors 88 are capable of accurately sensing the presence of a wagon within a predefined range, triggering water application via the spray head 54.

[0062] When a vehicle enters the detection range, the proximity 88 sensors activate the water spray mechanism. The sensors are fine-tuned to distinguish between different objects and movements, ensuring that the system only activates in the presence of a vehicle. This precision minimises unnecessary water spraying and conserves resources. Upon detection, the sensors 88 send a signal to a control unit, which is located within the control box 84, which promptly activates the water spray nozzles via solenoid valves (not shown).

[0063] The water spray nozzles are strategically positioned along bars 56a, 56b to cover the entire surface of the vehicle, reducing the time required for the watering process.

[0064] Maintenance and safety features are integral to the design of the system 10. The proximity sensors 88 and spray head 54 are easily accessible for routine inspections and servicing. Safety mechanisms are incorporated to prevent accidental activation and ensure safe operation. The system 10 includes a manual override function, allowing operators to control the watering process manually, if needed.

[0065] The system 10 works in three modes of operation, as follows:

[0066] 1) Manually. An operator turns the spray on, as required.

[0067] 2) Semi automatic. An operator turns the system 10 on. The system 10 will then spray onto the wagons stopping between each wagon. The system 10 turns itself off if nothing passes within 30 seconds.

[0068] 3)Automatic. The system 10 is activated when the locomotive passes the stanchion 18, there is then a few seconds time delay to allow the locomotive to clear the spray head 54 before the system 10 starts to spray water. The system then resets if nothing passes the sensor 88 within 30 seconds. In this way, the system 10 operates to discharge a volume of water onto the moving wagon below. In this way, the rail ballast that is contained in the wagon can be entirely wetted when the speed of the wagon is around a slow walking pace.

[0069] In order to increase the flow rate an alternative design of spray head 90, which is capable of discharging a wide angle and flow of water, is shown in Figure 3. The construction of the second embodiment of spray head 90 is very similar to that of the first embodiment and corresponding features have been given the same reference numerals. The second embodiment differs from the first embodiment in that instead of the spray bars 56a, 56b which can only deliver water from one single point to discharge through nozzles limiting the amount and pressure of water they can spray a higher flow rate spray head 90 is provided that can supply between 60 and 70 litres per second onto the wagon below. In this way, the locomotive can pull the wagons through at a brisk walking pace, perhaps upwards of 5 mph, such that the ballast in the wagon can be wetted more efficiently.

[0070] And as shown in Figure 3, the spray head 90 is configured having a generally discorectangular shape, having spaced-apart longitudinal spray arms 92a, 92b the ends of which are fluidly connected via semicircular ends 94.

[0071] Again the spray head 90 is supplied towards the centre thereof via a connector pipe 96, The connected pipe 96 itself curves downwards, as best shown in Figure 3. By minimising at all 90° bends and providing such a closed loop configuration, the skilled person will appreciate that the flow rate exiting from a series of nozzles 98 can be significantly increased. Such a closed loop configuration continuously circulates water, allowing for higher volumes and consistent pressure because water can flow around the loop 90 without losing pressure or volume at the endpoints.

[0072] Although not shown in Figures 1 to 3, the dust suppression system 10 of the present invention can optionally utilise rainwater capture and solar energy to ensure a reliable and uninterrupted power and water supply essential for sustaining dust suppression with minimal energy requirements and resource consumption. The skilled person will understand that the metalwork components forming the system 10 can be mild, powder-coated or galvanised steel, or the like. The metalwork components forming the system 10 can be assembled using any suitable form of metal fabrication, e.g., from a welded and bolted construction.

[0073] Therefore, a dust suppression method and system 10 is provided to efficiently and effectively control silica dust from rail ballast materials when being transported on open wagons on the rail network.

[0074] When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components. The singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and / or “including” when used herein, specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0075] When used in this specification and claims, the terms “ballast” refers to the mineral aggregate which forms the track bed upon which rail sleepers are laid. The skilled person will understand that “dust” is a loose material that predominately consists of small mineral grains that have been broken down over time.

[0076] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, separately, or in any combination of such features, can be utilised for realising the invention in diverse forms thereof.

[0077] The invention is not intended to be limited to the details of the embodiments described herein, which are described by way of example only. It will be understood that features described in relation to any particular embodiment can be featured in combination with other embodiments. It is contemplated by the inventor that various substitutions, alterations and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims.

Claims

CLAIMS1. A dust suppression system for controlling dust from rail ballast materials being transported in open wagons on a rail track, comprising: a gantry positioned above and spanning a section of the rail track, the gantry comprising a platform supported by stanchions, wherein the platform has an elongate opening configured orthogonally to the rail track; a spray head positioned within the elongate opening of the platform, the spray head comprising spray bars with nozzles configured to discharge water droplets onto the rail ballast materials being transported in open wagons; and a control system comprising proximity sensors to detect the presence of an open wagon and activate the spray head.

2. The system of claim 1, wherein the spray head comprising a pair of elongate spray bars configured in a spaced-apart arrangement, with a centrally-disposed connection pipe in fluid connection between the pair of spray bars.

3. The system of claim 2, wherein the nozzles on the spray bars are positioned on the underside thereof and configured to direct jets of water downwards onto the rail ballast materials.

4. The system of claim 1, wherein the spray head is configured to cover at least the track gauge of the rail track to ensure effective coverage of the rail ballast materials in the open wagons.

5. The system of claim 1, wherein the control system includes solenoid valves controlled by the control system to activate the water spray nozzles upon detecting the presence of an open wagon.

6. The system of claim 1, further comprising a spray head having a generally discorectangular shape with spaced-apart longitudinal spray arms and semicircular ends.

7. The system of claim 6, wherein the spray head has a closed loop configuration to enhance water circulation and pressure, with a connector pipe supplying water to the centre of the spray head.

8. The system of claim 6, wherein the nozzles on the spray head are configured to deliver a discharge flow rate of water of between 60 and 70 litres per second.

9. The system of claim 1, wherein the gantry includes anti-slip grating and safety handrails for operator safety.

10. The system of claim 1, further comprising a water tank tower in fluid connection with the spray head via a supply pipe which maintains water pressure and levels.

11. The system of claim 1, wherein the system operates in manual, semi-automatic, and automatic modes, with the automatic mode activated by the detection of a locomotive passing the stanchion and a subsequent time delay.

12. The system of claim 10, further comprising means for capturing rainwater to supply water to the water tank tower of the system.

13. The system of claim 1, further comprising solar cells and batteries to provide electrical power to the system.

14. The system of claim 1, wherein the gantry includes structural components such as crossmembers, cross braces, and comer pieces.

15. The system of claim 1, wherein the stanchions of the gantry are seated upon concrete structural bases and secured via bolted column connections.

16. The system of claim 1, wherein the gantry further includes a staircase leading to a ladder with a safety hoop for accessing the platform.

17. The system of claim 10, wherein the water tank tower comprising an elongate cylindrical tank seated on a structural concrete slab.

18. The system of claim 10, wherein the water tank tower includes stanchions, crossmembers, and cross braces.

19. The system of claim 10, wherein the water tank tower includes a ladder with a safety hoop for operator access.

20. The system of claim 10, wherein the water tank tower includes an anti-slip grating and safety handrail to ensure operator safety.

21. A method for controlling dust from rail ballast materials being transported in open wagons on a rail track, comprising: supplying water to a spray head from a water source, the spray head being positioned on a gantry above and configured to cover at least the track gauge of the rail track, the spray head comprising spray bars with nozzles configured to discharge water droplets onto rail ballast materials being transported in open wagons; detecting the presence of an open wagon beneath the gantry using proximity sensors; and activating the spray head and discharging water droplets from the spray head onto the rail ballast materials being transported in the open wagon.

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