Source-Capture Dust Collection Eliminates Airborne Silica Risk at a Cement Manufacturing Facility
■
Industry: Cement Manufacturing & Bulk Material Handling
Application: Woodworking Dust Collection & Combustible Dust Protection
Engineering at a Glance
Challenge
Airborne cement dust containing respirable crystalline silica (RCS) was escaping at key process points, creating employee exposure concerns, excessive housekeeping, and increased equipment maintenance.
AQE Solution
Engineered a custom source-capture dust collection system with strategically designed capture hoods, optimized conveying velocities, and centralized high-efficiency filtration.
Key Results
Reduced employee exposure to respirable crystalline silica
Improved equipment reliability
Supported OSHA permissible exposure limit (PEL) compliance
Cleaner, safer production environment
Significantly reduced housekeeping requirements
The Challenge
A cement manufacturing facility was experiencing excessive dust emissions throughout its production process. Fine cement dust escaped during mixing, conveyor transfers, and bagging operations, allowing respirable crystalline silica (RCS) to migrate throughout the plant and surrounding neighborhood.
The uncontrolled dust created several operational challenges:
Increased employee exposure to respirable crystalline silica
Accelerated wear on production equipment
Risk of exceeding OSHA permissible exposure limits (PEL)
Reduced visibility and overall plant cleanliness
Extensive housekeeping and cleanup requirements
Rather than filtering contaminated air after it had spread throughout the building, the facility needed an engineered solution that would capture dust at the point where it was generated.
AQE Engineering Assessment
AQE conducted a comprehensive evaluation of the manufacturing process, material transfer points, and existing ventilation system.
Our assessment determined that while the facility had general ventilation, it lacked effective source-capture collection at the locations generating the highest concentrations of airborne dust.
Engineering analysis identified three primary emission points:
Mixing operations
Conveyor transfer points
Bagging stations
Without localized capture, process airflow carried fine cement particulate into employee work areas before it could be effectively controlled.
The Engineered Solution
AQE designed a custom source-capture dust collection system engineered specifically for the facility's production process.
Key System Components:
Custom Source-Capture Hoods – Engineered to intercept cement dust directly at mixing operations, conveyor transfer points, and bagging stations before it could escape into the workspace.
Optimized Conveying Ductwork – Properly sized ductwork maintained transport velocities that prevented material settling while maximizing collection efficiency.
Centralized Industrial Dust Collector – Selecting two Scientific Dust Collector’s High-efficiency bag house collectors we removed fine cement particulate from the airstream before clean air was discharged.
Balanced Airflow Design – System airflow was engineered to maximize capture performance while minimizing energy consumption across the entire collection network.
By capturing dust immediately at its source, the system prevented respirable silica from migrating into employee breathing zones and throughout the facility.
Results
Improved Worker Safety
Capturing cement dust at its source significantly reduced airborne respirable crystalline silica throughout the production area, helping the facility support OSHA permissible exposure limit (PEL) compliance while providing a safer environment for employees
Reduced Housekeeping
Containing dust before it dispersed throughout the plant substantially reduced cleanup requirements, lowering maintenance labor while improving overall facility cleanliness.
Increased Equipment Reliability
Minimizing airborne particulate reduced dust accumulation on production equipment, helping decrease maintenance demands and improve long-term equipment performance.
Long-Term Operational Value
The engineered source-capture system provided a permanent solution that improved workplace safety, reduced operating costs, and enhanced day-to-day production efficiency without disrupting manufacturing operations.
Why AQE?
Industrial dust collection begins with understanding the manufacturing process—not selecting equipment.
AQE engineers analyze how contaminants are generated, how they move through a facility, and where they can be captured most effectively. By designing source-capture solutions around the process rather than around a catalog, AQE delivers systems that improve worker safety, support regulatory compliance, reduce operating costs, and provide long-term value
Download the Full Case Study Below
Fill out the form to get instant access to the complete case study and learn how we delivered real results for our client.