Fallout from bulk loading dry goods is now a thing of the past
with the development of DSH Systems Ltd (dust suppression
hopper) which fertilizer companies in New Zealand, Australia,
North and South America and South Africa have embraced to
control their dust and provide a cleaner and safer work
The hopper is the brainchild of New Zealand engineer Trevor
Schwass of DSH Systems Ltd and was originally developed for a
local New Zealand fertilizer plant to suppress the dust
generated by its bulk loading system.
The award-winning dust-free loading spout ingeniously
contains the dust within the product stream when discharging
dry bulk materials. Thus, it cleverly avoids the need for the more
complicated retractable or telescopic loading spouts that are
more commonly used in today’s truck loading and out-loading
Extensive research proves the Dust Suppression Hopper
works well on many different dry, free-flowing granular products.
Since the first hopper was developed for Ravensdown
Fertiliser in NZ, DSH Systems have commenced exporting to
other international fertilizer companies and bulk loading
Grant Allen, technical manager of lmpact Fertilisers P/L, Australia
reports. “Each year, Impact Fertilisers loads 120,000 tonnes of
single superphosphate for bulk shipment and around 200,000
tonnes for truck and container movements. This process
generated localized dust resulting in environmental complaints
for the wider community and OH & S issues. In order to meet
the safety and environmental values of the business the problem
had to be resolved whilst continuing to operate at commercially
competitive load rates.
An innovative solution was found in the form of DSH
Systems Ltd (dust-suppression hoppers). Installation and use of
these loading spouts at 12 locations around Australia has
resulted in significant reduction of fugitive dust emissions. This
has directly resulted in a significant improvement to the working
environment and dropped environmental complaints due to dust
from loading operations to zero.
All of this has been achieved with zero impact on the speed
of the loading operation and in some instances resulted in an
increased loading rate. The new system has been embraced by
all parties and now constitutes standard practice. This project
exemplifies sustainability by delivering sound environmental and
economic outcomes through the introduction of innovative
Ravensdown Fertiliser, one of New Zealand’s leading fertilizer
companies, has 49 hoppers in 35 stores throughout New
Zealand. Ravensdown’s lower North Island project manager
Hugh Eaglesome is thrilled with the hopper, which has limited
dust fallout, improved visibility and provides the perfect pour.
“We use the dust-suppression hopper on
our load-out points; truck and rail and also
the dress belt into store, a drop of about 14
“The hoppers have been a great success
in cutting down the dust problem and make
visibility a lot easier and provide a perfect
pour when loading.
“Not only are we happy, but truck drivers
and transport companies are thrilled as
there’s less debris over their trucks,”
Eaglesome says.
He endorses the hopper and says it could
easily be adapted for other bulk loading
Trevor Schwass, technical director, says
the system is now also successfully used for a
variety of dry, granular, free-running products including fertilizers,
stock foods, wheat, barley, sugar, sand and lime.
“As clients demand unique solutions, we endeavour to
develop the system for transferring specific products. The
development of larger hoppers means we can now service
clients with larger loading rates and also handle barge and ship
Lisa Brickey of Mosaic Crop Nutrition, Savage, Minnesota,
USA reports:
“We bought our first DSH hopper in 2007 and now have
four more installed. The DSH System allowed us better control
over our dust. The system requires no air, hydraulics or
electricity. There is no waste dust stream to handle and our
load out rate was not impacted at all. We had our first spout up
and running in 30 minutes!
“I had my doubts when I first saw the before and after
photos, but the system really does work that well! We love it!”
A small degree of natural agitation as the
hopper is filled helps exclude air from the
material being transferred. At the point of
loading or transferral, the DSH System
concentrates the discharge of dry goods as
a tight solid column through free air into
any target repository including trucks, rail
cars, ships, storage containers, bags or
stockpiles. Loading can be continuous
without plant interruption.
DSH Systems produces seven hopper
sizes manufactured from polyethylene, steel
and stainless steel to cover most
applications. Due to international demand,
the company is constantly researching and
developing systems to enable the efficient
transfer of a wider range of products.
Academic interest from international universities and consultants
continues to expand upon the research and science behind this
revolutionary system.
Associate Professor Peter Wypych, Centre for Bulk Solids and
Particulate Technologies, University of Woollongong, Australia
states: “The DSH Systems Ltd dust-suppression hopper can
achieve major reductions in fugitive dust emissions and also dust
explosion hazards. It will be a very useful tool for many bulk
handling engineers and technicians”.
DSH Systems exhibited at Powtech in Nuremburg in April
2010 with the intention of increasing its distribution network
into the northern hemisphere. Distributors have now been
appointed in the UK and Ireland and the Benelux region and
discussions are ongoing with other interested companies