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I-CAT offers end-to-end integrated dust-management solutions | DustMonster creates an ultra-fine mist that attracts dust encapsulating airborne particles.

I-CAT offers highly-effective dust-suppression systems for mines, based on extensive research and development, coupled with affordability. Thus it is able to provide end-to-end integrated dust-management solutions that comply with all relevant industry regulations and standards.

I-CAT has in-house capabilities to research and develop products to fit specific client solutions. Assessments are conducted on-site, and soil samples are extracted. “Once these have been analysed, we customise the necessary products and service in accordance with the client’s requirements. Each case is different,” I-CAT Dust Division Project Manager Wessel van der Westhuizen explains.

Site inspections are conducted, whereby I-CAT gathers all of the necessary information from the client in order to compile a base line of their current dust emissions. It then consults with the environmental department to determine the source of the dust being generated, which involves a full-scale analysis of the soil samples taken so as to be able to provide a tailored solution.

This includes daily, weekly, and monthly client reporting. “We are in constant contact with the client. Most importantly, we have personnel stationed at the mines to look after the projects at hand, and to ensure that the client’s expectations are met,” van der Westhuizen elaborates.

In addition, I-CAT conducts a thorough report on the effectiveness on all any systems supplied. It conducts regular trials for mines on different soil samples. “Trial-and-error is key to perfecting our products and systems,” van der Westhuizen stresses.

Main products in this regard include RDC 20, an innovative formulation of blended emulsified co-polymers and ionic modifiers. When sprayed onto the road surface, this water-soluble anionic polyelectrolyte polymer forms a durable cross-linked matrix. The matrix binds fine soil particles into larger heavier particles, which are less prone to become airborne.

GreenGrip is a natural polymer-based, durable gravel-road sealant. It is an environment-safe alternative to chemically-based products for semi-permanent gravel roads on mines and residential areas. It is water-soluble, and is incorporated easily into routine dust-suppression procedures, with no requirement for special equipment or handling precautions.

GreenBit is a natural binding agent combined with an emulsified bituminous product to create a durable gravel-road sealant. It is an environment-safe alternative to purely chemically-based products for permanent gravel roads on mines and residential areas. GreenBit was developed specifically for this application, and produces a durable, smooth and dust free surface that eliminates the need for frequent maintenance.

TDS 2005 is a unique, environment-friendly liquid gel used for dust suppression on tailing dams and large open soil areas. The unique properties of this liquid gel allow it to penetrate into the surface, creating a durable bond that binds the loose aggregate by forming a crust. In addition, mines have a number of challenges in reducing windswept dust on and around their tailing dams and open soil areas.

I-CAT has acquired the sole distribution rights for sub-Saharan Africa for state-of-the-art low-pressure misting systems from Europe. “We have modified and adjusted this world-leading technology for application in the industrial and mining sectors in Africa,” van der Westhuizen adds.

I-CAT also holds the sole distribution rights for an exciting new mist-nozzle system, developed and manufactured in Europe. It enables the user to have full control of the amount of water used – from minimal water usage, with no effect on the resource, up to higher levels of water use that increase the level of moisture in the material, which is desirable in some cases. This system is easy to install and operate.

The DustMonster product line provides outstanding results by creating an ultra-fine mist that attracts dust, encapsulating airborne particles, and driving them to the ground. In terms of customisation, RDC20 and GreenBit comprise a fixed formula that can be adjusted accordingly.

At present, I-CAT has numerous projects running in the Northern Cape for primary haulage roads and secondary roads. “We are also working on coal mines in Mpumalanga, as well as platinum and gold mines in the North West Province. We have major projects running internationally in countries such as Australia, Botswana, and Namibia, where the primary application is for road haulage on mines,” van der Westhuizen concludes.

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