Deploying a dust monitoring network is a multifaceted process that requires consideration beyond hardware and sensors. While many operations focus on acquiring physical devices, a comprehensive deployment addresses connectivity, data handling, software integration, and operational processes.
Combined with NIOSH, we implemented a tailored solution for Elk Valley operations to meet these unique challenges and improve dust monitoring and mitigation efforts.
The Challenge
Elk Valley operations faced distinct environmental and logistical challenges, including cold weather conditions, limited sunlight, and varied terrain. Additionally, traditional approaches to dust monitoring often lacked the adaptability and real-time insights required for effective mitigation strategies. The project’s goals included:
- Designing a system capable of withstanding extreme cold temperatures.
- Ensuring reliable connectivity and data transmission.
- Developing a scalable solution for monitoring dust and silica levels across a large, dynamic site.
- Providing actionable insights and real-time notifications to various stakeholders.
Our Approach
Our methodology combined robust hardware, advanced software, and a collaborative strategy with NIOSH to meet Elk Valley’s specific requirements.
1. Hardware Deployment
APT installed 15 custom-engineered Cold Weather MAXIMAs, stationary optical particle counters specifically designed for the site’s climate. Key features included:
- Heating Components: Integrated heaters to ensure reliable wind sensors and power systems performance in sub-zero conditions.
- Power Adaptations: Solar-based systems tailored to limited sunlight availability, with backup power capable of sustaining operations for up to a week without sunlight.
- Environmental Sensors: Measurements included particle concentrations, temperature, humidity, and pressure, enabling comprehensive data collection.
- GPS and Tip Indicators: Added for enhanced monitoring and recovery of displaced units.
2. Connectivity and Data Handling
Reliable data transmission was critical for real-time monitoring. We employed Wi-Fi and cellular connectivity options, balancing speed and deployment flexibility based on site-specific needs.
Despite terrain challenges, the APT system achieved low latencies, typically within a few seconds.
3. Software Integration
We developed a cloud-based platform for data aggregation and analysis, incorporating:
- APT Dust Model: Algorithms to generate a continuous dust heat map.
- Real-Time Dashboard: Visualizing sensor data, wind patterns, and dust migration trends.
- Custom Notifications: Configurable email alerts tailored to operational needs, including time-based and trigger-based notifications.
4. Adaptive Design
Our system emphasized versatility, allowing real-time adjustments based on feedback and operational changes. Data was collected and analyzed every 30 seconds, ensuring timely updates for decision-making.
APT MAXIMA Data Quality
The accuracy and reliability of the data collected by each MAXIMA unit were paramount. APT's commitment to data quality includes:
- Sensor Calibration: Each Maxima was calibrated to ensure precise measurement of particle concentrations, temperature, humidity, and pressure.
- Fog and Rain Correction: Custom correction factors were implemented to address environmental conditions like fog and rain, ensuring data integrity.
- Data Upload Protocols: A combination of Wi-Fi and cellular networks ensured uninterrupted data transmission. Redundancy protocols were in place to mitigate potential connectivity issues.
- Real-Time Monitoring: Continuous performance checks allowed the system to self-diagnose and alert operators to anomalies, minimizing downtime.
- Feedback Loop Integration: The system’s design incorporated a feedback loop, allowing the operations team to validate data accuracy through on-site observations and adjust parameters as needed.
Results
The integrated system delivered significant improvements in monitoring and managing dust risks:
Operational Insights
- Dust Mapping: A 2,500-grid heat map updated every 30 seconds provided granular insights into dust concentrations and migration.
- Variability Analysis: Highlighted significant spatial and temporal variations, enabling targeted interventions.
Stakeholder Collaboration
- Conducted a workshop with environmental, operational, and maintenance teams to gather feedback and refine the system.
- Key outcomes included a unified dashboard, tunable notifications, and alert acknowledgement features.
Improved Safety and Compliance
- Real-Time Notifications: Enabled proactive responses to elevated dust and silica levels.
- Actionable Data: Supported policy decisions, such as respiratory protection requirements during high-risk periods.
- Feedback Loop: Regular qualitative feedback ensured alignment between observed conditions and system outputs.
Conclusion
Effective deployment requires addressing environmental, logistical, and operational factors from the outset.
Furthermore, collaboration with on-site teams requires practical, actionable solutions for dust monitoring.
Our partnership with Elk Valley operations demonstrates the value of an integrated, end-to-end approach to dust monitoring. By combining advanced technology with operational expertise, we provide a system that meets current needs and offers scalability for future enhancements.
The result is a safer, more efficient operation with actionable insights for dust risk management.
Take a tour of APT's dust management platform
Vulcan Materials Company is the nation’s largest producer of construction aggregates.
Project partner
Brent Leclerc | Environmental Manager
Problems solved
Unjustified community dust complaints & lawsuits
Difficulty complying with opacity regulations and risk of NOVs
Solution
Real-time dust monitoring
Dust maps proving no community impact, preventing fines & lawsuits
Real-time opacity monitoring, high degree of compliance
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