Synergy Spray System new logo
Synergy Spray System new logo

DUST SUPPRESSION SYSTEM AND DUST CONTROL SYSTEM

Synergy Spray Systems is a leading dust suppression system manufacturer in Chennai, India, specializing in the design and production of dust suppression cannons, dust suppression chemicals, and misting systems. As trusted experts in dust control solutions and air pollution control equipment, we deliver high-quality and reliable products to industries across India.

Our comprehensive range also includes water spray nozzles, dust control spray equipment, and customized dust settlement systems, designed to meet the needs of mining, construction, cement, and other heavy-duty industries. With a strong focus on innovation and performance, Synergy Spray Systems ensures effective dust suppression and cleaner working environments
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DUST CONTROL SYSTEM

SYNERGY SPRAY SYSTEMS supplies and integrates Dust Suppression & Control System technology in India for various applications including Manufacturing, Industrial, and Mining applications. Dust Settlement solutions can be offered in different ways depending on the size and the type of dust particles. Our dust control technology ensures an optimal approach to both odour and dust problems by producing fine water particles that effectively trap the dust and settles down the dust particles effectively making the work environment better for employees as well as the environment. Dust suppression system working principle is based on the agglomeration of dust particles with similar-sized water particles and it is considered as one of the best available technology for air pollution control in Industries. Water spray systems and industrial misting systems are widely used in dust control and dust management. Tags: industrial misting systems dust control | water spray system for dust control

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DUST SUPPRESSION SYSTEM

Our Dust Suppression Systems using misting is designed in accordance with industry standards. With our own R&D, production and after-sales provide the perfect solution to solve your dust problem. We use high-pressure water fogging / misting which creates a fine fog consisting of very fine water droplets (less than 10-micron size) in diameter. These tiny water droplets absorb even the smallest dust particles in the atmosphere without making the ground wet there by improving air quality. It is best suited for very dusty environments. We offer both indoor and outdoor dust suppression as per customer requirements and location.

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ADVANTAGES:

• Custom designed installations can reduce dust to lower levels as per regulations set by Pollution Control departments Improving air quality,  environmental and worker safety standards.
• Smallest misting / fogging droplets give maximum dust control without wetting the area.
• Inexpensive to operate: Low water and electricity consumption save running costs
• Low Operating & Maintenance Cost,  Operating at 70 bar / 1000 PSI.
• Low Maintenance: With no moving parts in the fogger, you will have years of reliable low-maintenance operation. ( Around10 micron)

DUST SUPPRESSION WATER CANNONS

Synergy Spray Systems provides a variety of water-based dust suppression cannons and suppression equipment designed for effective dust control in environments such as opencast mines, demolition sites, recycling plants, storage depots, loading systems, landfill sites, woodworking shops, and construction sites. Our robust, streamlined chassis offers durability and reliability, available in multiple models with projection distances ranging from 30 to 80 meters. Each unit is equipped with essential components, including a transfer pump, oscillation system, solenoid valve, filter, and pressure switch to ensure optimal performance and protection. We also offer customized solutions, allowing cannons to be mounted on either trucks or specialized trailers.
 
Our dust suppression equipments like fog cannons also have a long projection range and integrated 360° rotatable function suitable for dust control applications covering large areas and its the best dust control spray equipment.
 
Our patented nozzle head and the outer nozzle ring generate a finely atomized mist, which binds the dust particles and prevents them from spreading out of the confined area. The projection distance of the inside nozzle head can be limited to close range by switching off the turbine. In addtion to manufacturing of fog Cannons, we also mount dust suppression tank system on truck and mist cannons with tank.

DUST SUPPRESSION MISTING SYSTEM

This type of suppression methods deploys high-pressure water misting/fogging system which creates a fine fog consisting of very fine water droplets (less than 10-micron size) in diameter. These tiny water droplets absorb even the smallest dust particles in the atmosphere without making the ground wet and best suited for dusty environments and the best available option to control air pollution around Industries. The size of the misting particles produced varies from 10 microns to 100 microns based on the type of dust particles. fogging system for dust control is the cost effective way to control  without the use of binding chemicals to suppress dust.

Tags: fogging system for dust control
Dust Suppression nozzle

FAQ & RESOURCES

 How do I size a high-pressure misting pump for dust suppression?
Flow: sum all nozzle flow rates (L/min) × 1.10–1.20 safety factor.
Pressure: P_required = P_nozzle + pipeline losses + 10–15 bar margin.
Example: 60 nozzles × 0.15 L/min = 9.0 L/min → with 15% margin = 10.35 L/min. If nozzles need 70 bar and line loss ≈ 5 bar, select a pump ≈ 85 bar @ 10.5 L/min.
 What droplet size should I target for different dust?
• Respirable silica/ore fines (PM2.5–10): ~10–50 µm (dry fog 1–10 µm when oversaturation must be avoided).
• Coal, limestone, aggregates: 30–200 µm (HP mist or fine cone).
• Wood/organic dust: 50–300 µm (overspray-tolerant).
Rule of thumb: match droplet same order of magnitude as dust; too large → slipstreaming, too small → drift.
How many nozzles do I need at a conveyor transfer point?
• Cover 1.2× belt width across the plume.
• Spacing: 0.8–1.2 m between nozzles on a header; aim 30–45° into the plume.
• Treat 3 zones: loading chute, mid-transfer, discharge skirt. Interlock with belt-run & chute level sensors.
 What’s the design approach for dump hoppers & stockpiles?
• Dump hoppers: ring manifold (two rows), opposing fine-cone nozzles to form a fog curtain; photocell trigger.
• Stockpiles: oscillating cannons (throw 30–100 m), program sweep angles vs. wind; add edge mist rings at reclaim points.

 What water quality/filtration do high-pressure systems require?
• Filtration train: 20 µm → 5 µm → 1 µm (final).
• Scaling control: softening/anti-scale; use RO where hardness is high to protect 50–80 bar pumps and micro-orifices.
• Keep free chlorine low for stainless longevity; use SS316 in corrosive atmospheres.
 Will the system wet my product? How do I prevent it?
• Use dry fog (1–10 µm) or very low flow HP mist, short duty cycles, VFD pump control.
• Add surfactants only when needed and at low dose.
• Place nozzles above plume with cross-fire, not directly onto product.
How do I estimate energy & water consumption?
• Water (L/h) = total L/min × 60 × duty cycle.
• Motor kW ≈ (Q[L/min] × P[bar]) / (600 × η).
Example: 10.35 L/min @ 85 bar, η=0.8 → ~1.83 kW, water ~621 L/h at 100% duty.
What automation improves efficiency?
• Sensors: PM monitors, humidity, belt-run, chute level, wind.
• Controls: PLC/SCADA, VFD on HP pump, zone valves, time-proportioned pulsing.
• Interlocks: conveyor trip → instant spray cutoff; wind-based cannon slew/flow.
Which materials, enclosures, and ratings should I specify?
• Wetted parts: SS316 for corrosive/chemical; SS304 for general.
• Enclosures: IP65+ for outdoors; UV-stable hoses.
• Hazardous areas: specify ATEX/IECEx or equivalent for dust Zones 21/22; TEFC/Ex motors as required.
 Dry fog vs. High Pressure mist vs. sprinklers vs. cannons — when to use?
• Dry fog (1–10 µm): minimal wetting; chutes/transfer points; needs clean dry air and fine filtration.
• HP mist (10–50 µm): general industrial, flexible zoning, low water use.
• Sprinklers (100–1000 µm): yard dust & roadways; high water, low finesse.
• Cannons: long-range open areas, stockyards; add wind logic to cut drift.
What’s a practical maintenance schedule?
• Weekly: check filters, strainers, leaks, nozzle pattern; drain separators.
• Monthly: flush headers/lines; inspect belts/couplings; clean nozzle tips.
• Quarterly: service pump (oil/seals per OEM), calibrate sensors; verify relief valve & gauges.
How do I document compliance & effectiveness?
Baseline PM2.5/PM10 readings, capture before/after at fixed locations, log duty cycles/flow, keep SOPs, HIRA/JSA, and maintenance records aligned to local standards (e.g., CPCB/OSHA guidance).
What data should my RFQ include for accurate sizing?
Dust source & process, throughput (TPH), particle characteristics, belt width/speed, indoor/outdoor, target reduction, available power/water/air, water analysis, ambient temperature/RH/wind, control integration (PLC/SCADA), hazard classification, corrosion class, and preferred materials.
Can I run dry-fog on existing compressed air?
Yes—provide clean, dry air (CDA) with adequate flow, stable pressure, filtration to oil/water-free, and a dew point below the lowest ambient to prevent icing.
How do I retrofit on running conveyors with minimal downtime?
Use clamp-on manifolds, flexible high-pressure hoses, quick-disconnects, skid-mounted pump/filter sets, pre-wired control panels; commission zone-by-zone during planned micro-stoppages.
For Spray Nozzles: +91 94442 75778
For Spraying Systems and
Dust suppression system: +91 86100 00128
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