Benmarc Environmental (Pty) Ltd specializes in Total Dust Management (TDM®) products and services. Benmarc is headquartered in Johannesburg. Our international affiliate organizations are located in Batavia, Illinois (Corporate Headquarter); Deuben, Germany and San Nicolas, Aruba. Amerex Industries, Benmarc Environmental’s process gas conditioning affiliate, SPE-Amerex, is headquartered in Batavia USA, with branches in Pittsburgh.
As a result of Benmarc Environmental’s International footprint, design and engineering work is done on an international level, drawing from the expertise and experiences of a wide variety of solutions to each situation and / or unique customer requirements developed over the last 30 plus years.
Benmarc Environmental’s total international dust suppression systems treat over 380,000,000 tons of ore / material per year, from coal to iron ore, to lime and Kimberlite and everything in between. Benetech Inc, a US company and licensor to Benmarc Environmental, treat over 900,000,000 tons of material annually.
The company fabricates its own dust suppression systems, modularized to minimize both installation cost and time. Benmarc Environmental’s project management capability can take a project from inception through start-up. Fully equipped and trained local staff provides on-site maintenance service, as well as on-site commissioning and optimization programs.
As its core business since inception, Benmarc offers a full scope of dust management products and services that support regulatory compliance while minimizing the impact of adding moisture to the product being suppressed, with residual effects where applicable.
The dust management program frequently begins with a comprehensive dust management audit of the facility. This audit provides a technical needs assessment, risk management action plan, and budgetary cost estimates to allow management to prioritize an action plan based on risk and budgetary constraints.
The products used by Benmarc have been specifically designed for each application. Our 210E deals with immediate and short-term dust suppression at truck tips, crushers, crusher outlets and apron feeders. Our 515E deals with mid-term suppression and is mainly applied to the stockpile, providing dust suppression through the stacking and reclamation process for a period of up to 16 days. Other uses of the 515E include covering multiple transfer points with one application point, and recently, suppressing the loading AND offloading of train-loaded material from source to delivery point.
As of January 2009, all our products were re-engineered and re-formulated, removing ALL chemical components, and replacing these with locally-sourced, naturally-derived environmentally-friendly products. Our new products are significantly cheaper than the old chemical blends, yet provide an improved level of dust suppression over their already superior dust suppression. The products are now referred to as ‘suppressants’ and not chemicals, so as to avoid any negative connotation associated with the term ‘chemical’.
Benmarc Environmental provides a full scope of dust management programs including dust suppressants, application systems, containment system components, collection, design engineering, turnkey installations, and the follow-up field services required for a successful dust management program.
These products and services have effectively been deployed at many facilities throughout SA and surrounding countries, especially those using iron ore, coal, kimberlite and such like products. Benmarc Environmental prides itself in the relationships it forms with customers who will attest to the success of our dust management programs.
Total Dust Management represents a comprehensive range of technologies and services associated with all aspects of bulk material handling. With over 20 years of dust control experience, Benmarc Environmental’s TDM approach assures the best solutions to a facility’s unique needs. Benmarc Environmental is the only company that offers a comprehensive approach that can include:
- Needs/Condition Assessment
- Chemical Suppression Systems
- Fabric Filter Collection Systems
- Containment Systems
- Compliance Dust Level Audits
- Turnkey Installation / Start up
- Engineering Services
- Chute / Transfer Design
- Fire Suppression Systems
- Wash down Systems
- Haul Road Chemicals
- Dust Agglomeration / Transfer
- Flexibility in Contracting
Unquestionably, performance and cost are two of the major factors that are used to evaluate a supplier. Regarding performance, whether it is product, equipment or service, Benmarc Environmental excels. With its own highly qualified and diverse technical staff, the company practices an engineered approach in determining the dust management requirements for a plant or mine. Whether it is a requirement for containment, suppression, collection, maintenance, and/or re-engineering, the most cost effective solutions are proposed to meet each facility’s requirements.
Refer subsequent table detailing our client base, including the materials treated, tonnages, key contact personnel etc.
Applications at these sites range from truck tip and crusher suppression, stockpile suppression to haul road dust suppression and the supply of PACs, the Benmarc-designed device that is used to unblock chutes.
SERVICE PROGRAMME (optional)
Benmarc Environmental can offer to the client a service program in which all aspects of the specified service requirements shall be met. Benmarc Environmental utilizes full-time, trained service technicians to conduct thorough and effective service and maintenance tasks. In addition, Benmarc Environmental shall incorporate any engineering support required to enhance system operation, availability and performance. Benmarc Environmental’s service program consists of the following, and is expanded on in the pages following:
Routine service and maintenance for the dust suppression system.
Monitor dusting trends.
Benmarc Environmental currently has maintenance agreements in place with the following sites:
Assmang Load-Out (I & II);
ARM Nkomati JV;
Assmang sites in the Northern Cape, Jwaneng and ARM Nkomati JV, each have their own dedicated full-time Benmarc Field Service Technician on site.
Other sites are serviced weekly, and the amount of time spent on site is at the customer’s discretion, however, full-time maintenance is recommended to ensure the best results are achieved utilizing trained FST personnel.
Periodic Service and Maintenance
Qualified Benmarc Environmental service technicians shall conduct the following periodic services, amongst others:
Provide detailed service reports;
Maintain all BENMARC ENVIRONMENTAL supplied equipment;
Monitor system performance to include, but not be limited to:
Calibrate chemical pumps;
Check/clean spray nozzles;
Verify and document flows;
Clean pumps and enclosures;
Document chemical inventory;
Provide off-loading monitoring (of chemicals).
Benmarc Environmental has at the client’s disposal, a department of engineers within Benmarc Environmental to assist the field staff in system enhancement, programming logic, system design, increased system reliability and effectiveness.
Included as part of the DSS supply as part of this tender, is a multi-channel remote-monitoring and logging device, that will provide on-line and real-time values of the product tank levels on site. This device will be programmed to provide early notification of low tank levels, incorporating standard lead times experienced on site, so as to ensure that the system never runs dry and is always available to provide the necessary level of dust suppression. At other locations where this device is not yet installed, field service technicians perform this task manually and provide the necessary feedback to the mine personnel.
Monitor dusting trends
This can be done in two ways, both leading to a dust monitoring report which can be used for regulatory reporting and in-house monitoring. The use of our DSS and the results to be achieved can easily seen visually, but visual evidence is not sufficient for regulatory reporting, hence the dust monitoring options.
Option 1 is to have one of our field service technicians perform the task on site, through the use of one of our real-time dust monitors. The frequency at which this task is performed depends on the client requirements, and can be done monthly, quarterly, semi-annually and annually. Dust readings are taken with the DSS OFF for a predetermined period of time, and then with the DSS ON. A report is then compiled and submitted, displaying the results graphically. This proves the substantial reduction in dust levels through the use of our DSS, and can be put on file for regulatory reporting, should it be needed.
Option 2, already discussed under ‘PRODUCTS’, is the installation of real-time on-line dust monitors at strategic points around site. These units provide up to the minute dust readings, as well as immediate notifications and early warnings of dust peaks at the monitoring stations. The information is also logged, and monthly reporting is as simple as downloading the graphs for the period of time. The units also incorporate wind speed and direction sensors, which assist in determining the true source of dust generated.
The point where we are heading with our combined offering, is to have the remote-monitoring device installed as part of the DSS, monitoring not only product tank levels, but also water usage, tonnage treated and dust levels generated.
At the end of each year, a report can then be provided, detailing exactly how much product was used, related to water usage which confirms total moisture addition, and tonnage treated, which confirms the Rand cost / ton. In addition to this, dust levels and the reduction thereof through the use of our DSS can be shown in black and white.
For internal purposes, dust levels generated vs. the operation of the DSS can also be generated, ie we are able to monitor and track when the system is functioning vs. what dust levels are generated as a result.
Please do not hesitate to contact us should you have any questions.