Background
Dalrymple Bay Coal Terminal (DBCT), located in Mackay, Queensland, forms part of the largest coal export port in the world and handles up to 85 million tonnes of coking and thermal coal each year.
To support these large-scale operations, DBCT employs a range of processes and tools to minimise and control dust emissions, including sprinkler systems, water and vacuum trucks, coal handling techniques and infrastructure design.
A key component of this system is stockpile veneering for dust suppression, which plays a critical role in managing fine particulate matter.
Challenge
Operating at significant scale, DBCT remains highly conscious of the impact of its production activities on surrounding beachside communities and its responsibility as a key operator within the Port of Hay Point.
The terminal is committed to maintaining best practice dust management outcomes while consistently operating below required management objective levels.
Despite an established and comprehensive dust reduction and management system, it remains impossible to completely prevent all coal dust emissions.
This creates an ongoing operational challenge to further strengthen dust suppression performance, particularly across stockpiles exposed to high wind conditions and environmentally sensitive areas.
DBCT engaged Vital Chemical’s team of technical experts for a solution that could be integrated into the site’s broader dust management strategy.
Solution
Vital Chemical addressed this challenge through the implementation of Vital Bon-Matt CDS 300, a uniquely formulated and completely natural polymer designed for the efficient control and stabilisation of fine, light and problematic mineral dust.
Vital Bon-Matt CDS 300 is a concentrated liquid emulsion that is diluted with water prior to application and applied as a coating to bind dust particles.
Once applied, Vital Bon-Matt CDS 300 forms a strong and flexible veneer with high water and wind resistance, as well as elasticity and tensile strength suited to demanding operating environments.
The formulation cures within hours and will not remobilise, ensuring consistent and durable performance across stockpiles and transport veneering applications.
Vital Bon-Matt CDS 300 has been specifically designed for use in non-trafficked, high-wind environments where durable and flexible surface conditions are required.
Its completely biodegradable formulation has been independently assessed, confirming that dilute residues of Vital Bon-Matt CDS 300 are expected to have little to no impact on dissolved oxygen levels in receiving waters.
The formulation of Vital Bon-Matt CDS 300 delivers effective dust abatement while creating a strong and flexible surface veneer that is capable of rebinding with successive water applications, thereby prolonging its effectiveness.
In addition, Vital Bon-Matt CDS 300 is free from polyacrylamide resins, magnesium chloride, solvent-based oils, coal-tar coatings and heavy or trace metals, ensuring a completely environmentally and workplace safe solution.
The use of Vital Bon-Matt CDS 300 also supports water conservation, improves visibility, reduces risk, increases productivity and contributes to cleaner air outcomes for workers, equipment and nearby communities.
Result
Dalrymple Bay Coal Terminal reported a consistently positive experience following the implementation of Vital Bon-Matt CDS 300, with no negative effects observed on the workforce, the immediate site environment or the quality of the customer’s product.
Vital Bon-Matt CDS 300 proved to be an effective veneering agent when applied correctly and delivered reliable dust suppression performance in a complex, high-exposure operational environment while remaining a competitively priced solution.
In addition to product performance, DBCT experienced exceptional support from Vital Chemical throughout the project lifecycle.
Vital Chemical provided immediate technical assistance and advice during trial stages, supplied the required infrastructure including pumps, pipework and fittings, and delivered training for site personnel as required.
This was complemented by prompt and efficient product resupply, ensuring continuity of operations and reinforcing the overall success of the project.