NIOSH deploys APT dust sensors in silica monitoring study

Applied Particle Technology (APT), a leading dust management platform for heavy industrial companies, has been featured in a comprehensive study conducted by the National Institute for Occupational Safety and Health (NIOSH). 

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The study, focusing on real-time dust monitoring in occupational environments, highlights the potential of low-cost dust monitors (LCDMs) to revolutionize dust management and improve workplace safety. 

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This article summarizes the findings from the NIOSH study. 

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Introduction to dust monitoring challenges

Respirable crystalline silica (RCS) poses a significant health threat to workers in various industries, including mining, construction, and manufacturing. Prolonged exposure to fine silica particles can lead to severe lung diseases such as silicosis and lung cancer. Traditional dust monitoring methods involve collecting time-weighted average samples for laboratory analysis, which, while accurate, do not provide real-time data. This limitation hampers the ability to address hazardous dust levels promptly.

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The advent of low-cost dust monitors (LCDMs)

NIOSH's study explores the use of LCDMs, which are significantly more affordable than traditional dust monitors. These sensors, originally developed for air pollution monitoring, can generate real-time data with high spatial and temporal granularity. Costing less than $300 per unit, LCDMs offer a stark contrast to the $5,000 average cost of traditional mining-specific dust monitors.

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Case study: Implementation in a Wisconsin mine

The study was conducted over a year at a sand mine in Wisconsin, where NIOSH researchers collaborated with the mine's industrial hygiene professionals. The goal was to assess the feasibility and effectiveness of using LCDMs for real-time dust monitoring. Five LCDMs were installed across two buildings with high dust concentrations: the screen house and the dry house.

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Installation and data collection

The sensors were strategically placed based on dust concentration hotspots and the availability of power and Wi-Fi. Each sensor recorded particulate matter (PM1, PM2.5, PM10), temperature, and humidity data at 15-second intervals. To ensure accuracy, gravimetric dust samples were also collected and compared with the sensor data.

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Findings and benefits of LCDMs

The study demonstrated several key advantages of using LCDMs for dust monitoring:

1. Cost-Effectiveness and Accessibility: The low cost of LCDMs makes them accessible for widespread use, allowing for extensive dust monitoring networks without significant financial burden.
2. ‍Real-Time Data Generation: Unlike traditional methods, LCDMs provide real-time dust concentration data, enabling immediate response to hazardous conditions and operational changes.
3. ‍Increased Spatial and Temporal Granularity: The high-resolution data from LCDMs allows for detailed analysis of dust patterns, identifying specific times and locations of elevated dust levels.
4. ‍Continuous Monitoring: LCDMs can operate continuously, providing a comprehensive overview of dust exposure throughout the workday and across different seasons.

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Overcoming challenges

Despite the benefits, the adoption of LCDMs faces some challenges, including concerns about analytical performance, complexity of use, and a lack of understanding of their value. The study addressed these concerns by validating the sensor data against gravimetric samples and providing training to the mine's industrial hygiene team on interpreting the data.

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Practical applications and future implications

The real-time data from LCDMs proved invaluable in several ways:

• Operational Adjustments: The mine was able to identify and mitigate dust sources by adjusting screening sizes and improving ventilation systems.
• Event Monitoring: Dust levels were monitored before, during, and after events such as shift changes, maintenance activities, and adverse weather conditions.
• Data-Driven Decisions: The detailed dust maps and time-series data allowed for informed decision-making and proactive dust management strategies.

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Collaboration and data management

A key aspect of the study was the collaboration between NIOSH researchers and the mine's team. Weekly automated reports were generated using custom scripts, providing a user-friendly overview of dust levels and trends. This streamlined data management approach ensured that both researchers and mine operators had access to up-to-date information.

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Conclusion

The study highlights LCDMs' significant potential in enhancing dust management in industrial environments. These low-cost sensors can complement traditional monitoring methods by providing real-time, high-resolution data, offering a more comprehensive and proactive approach to managing respirable dust hazards. 

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This case study sets the stage for the broader adoption of LCDMs in various industries, paving the way for improved occupational health and safety practices. As technology continues to evolve, the integration of such innovative monitoring solutions will be crucial in safeguarding workers' health and ensuring compliance with regulatory standards.