MONITOR. COMPLY.
SUPPRESS.
One platform for industrial air quality: continuous baghouse and particulate monitoring, EPA-defensible regulatory compliance records, and closed-loop mist / dust-suppression control. Differential pressure, opacity, stack temperature, PM2.5/PM10, CO₂, VOC, H₂S — measured 24/7, logged for auditors, and used to trigger fog cannons and misting the moment dust climbs.
VISIBLE EMISSIONS = FINES + SHUTDOWNS.
Cement plants, battery manufacturers, and heavy-industry sites face increasingly stringent emissions regulations. A single baghouse bag failure can trigger an EPA violation, costly fines, and forced shutdown. Manual inspections happen weekly at best — by then, the violation is already on record. DustIQ catches the failure in minutes, not weeks.
MEASURE CONTINUOUSLY. PROVE COMPLIANCE. SUPPRESS AUTOMATICALLY.
Sensor Each Dust Source
Differential pressure across every baghouse. Opacity stack monitor. Temperature, fan status, PM2.5/PM10 at stack, fenceline, and work areas. Wireless install. No conduit, no IT involvement. Class I Div 2 hazardous-area variants for explosive dust environments.
Monitor Continuously
Live status grid updating 24/7: BH-01 Normal, BH-02 Warning, BH-03 Critical. Differential pressure and opacity trends, PM concentration, fan status. Manage by exception — supervisors only react to deviations, not routine readings.
Prove Regulatory Compliance
Every reading timestamped, sensor-tagged, and stored immutably. EPA-defensible audit trail with chain-of-custody. Auto-generated 40 CFR Part 60/63 emissions reports and fenceline summaries. When the auditor asks, you don't dig through clipboards — you click "export."
Trigger Mist Suppression
Closed-loop control: when PM or opacity climbs past a threshold, DustIQ automatically fires fog cannons, misting rings, and dust-suppression sprays — then verifies the concentration drops. Every actuation is logged as proof of a good-faith dust-control response.
EPA-DEFENSIBLE AIR QUALITY.
MONITOR. REGULATE. SUPPRESS.
Baghouse Differential Pressure
Continuous dP monitoring across each baghouse compartment. Catches bag failures, broken pulse-clean valves, blinded filters. Class I Div 2 rated for combustible dust environments.
Particulate Matter (PM2.5 / PM10)
Real-time PM measurement at stack, fenceline, and ambient. ASHRAE 62.1 and EPA-grade reference variants. Outdoor station with weather (NO₂, O₃, SO₂, wind, rain) for full site air quality.
Regulatory Compliance Reporting
Auto-generated 40 CFR Part 60 / 63 emissions reports, opacity summaries, and fenceline air-quality logs. Excursion and exceedance flags with the exact timestamp, sensor ID, and the suppression response that followed. Export auditor-ready PDF or CSV in one click.
Closed-Loop Mist & Dust Suppression
DustIQ drives fog cannons, misting rings, and atomized-spray suppression from live PM and opacity readings. Threshold crossed → suppression fires → concentration re-checked. No manual valve turning, no over-watering — and every actuation is logged.
Stack Opacity & Temperature
Continuous stack opacity (EPA Method 9 equivalent). Stack temperature for thermal compliance. Tied to baghouse alerts and suppression — an opacity spike both notifies ops and can trigger misting automatically.
Continuous 24/7 Monitoring
Every dust source watched around the clock, not on weekly rounds. Live status grid, trend history, and manage-by-exception alerts. Replaces clipboard inspections with a permanent, queryable record.
EPA-Defensible Records
Every reading timestamped, location-tagged, and stored immutably. Chain-of-custody from sensor to report. 40 CFR Part 60 / 63 audit-ready with the suppression event tied to each excursion.
Indoor Air Quality
CO₂, VOC, PM, T°, RH for offices, control rooms, plant floors. ASHRAE 62.1 thresholds. Live at JAX International terminals and Campus360 K-12 deployments.
Live at Clarios + IAC Cement Plants
14 sensors in Clarios Toledo oxide rooms. 100+ baghouse systems across IAC engineering deployments in cement, mining, and battery manufacturing.
IN PRODUCTION
Baghouse + rotating equipment monitoring in oxide rooms. EPA-defensible audit trail. Manufacturing reliability + air quality compliance on one platform.
Continuous monitoring across cement plant baghouses. Reduced downtime by 10–20%. OEE improvements of 5–15%. $300K/day-of-downtime risk mitigated at each 1 MTPA plant.
Suspension preheater, raw mill, electrostatic precipitator, rotary kiln, packing house — every dust source monitored. Replaces manual rounds. Avoids visible emission events.
COMMON QUESTIONS
WILL IT INTEGRATE WITH OUR EXISTING CEMS?+
Yes. DustIQ complements continuous emissions monitoring systems (CEMS) — it doesn't replace them. We provide higher-frequency dP and PM data feeding into your existing 40 CFR compliance program. Modbus, OPC UA, or REST integrations.
ATEX / CLASS I DIV 2 VARIANTS?+
Yes. The baghouse dP monitor is Class I Div 2 rated for combustible dust environments. ATEX Zone 21/22 variants available for European cement plants and grain handling.
HOW DOES THE EPA AUDIT TRAIL WORK?+
Every sensor reading is timestamped, sensor-ID-tagged, and stored immutably in IoTLogIQ. Exports as auditor-ready PDF or CSV. Chain-of-custody preserved from sensor through cloud. Compliant with 40 CFR Part 60, Part 63, and state-equivalent regs. Each opacity or PM excursion is linked to the suppression response that followed, so the report shows both the event and your reaction to it.
CAN DUSTIQ ACTUALLY CONTROL OUR MIST / FOG SUPPRESSION?+
Yes. DustIQ closes the loop: when PM2.5/PM10 or opacity crosses a threshold, it sends a command to fire fog cannons, misting rings, or atomized-spray nozzles through relay, Modbus, or OPC UA, then re-checks the reading to confirm the concentration dropped. You set the thresholds per zone; DustIQ handles the actuation and logs every cycle. It can also run advisory-only, alerting an operator instead of actuating.
DOES AUTOMATED MISTING WASTE WATER?+
No — that's the point of tying it to live PM readings. Instead of running suppression on a fixed timer, DustIQ only mists when dust is actually rising and stops once concentration is back under threshold. Customers see lower water and pump-energy use versus timer-based systems, plus proof they suppressed exactly when it mattered.
WHAT'S THE ROI?+
Customer data: 10–20% maintenance cost savings, 5–15% OEE improvement (McKinsey cement industry benchmark). At a 1 MTPA cement plant, one avoided unplanned downtime day = $300K. DustIQ pays back on the first prevented bag failure.
CAN WE DEPLOY ON ONE BAGHOUSE FIRST?+
Yes — that's the standard pilot. One baghouse, one operations owner, 90 days. Pilot scales to plant-wide deployment, then to multi-plant network on the same platform.
PILOT IN 30 DAYS.
One area. One owner. One problem. Live data on the call, not slides.