From Rock to Risk: Rethinking Dust in Modern Mining
How Mineral Science and Monitoring Are Changing Site Safety
At the 7th Annual Dust and Respiratory Health Forum, hosted by the University of Queensland, Professor Nick Cook of the WH Bryan Mining Geology Research Centre (BRC) shared some deeply relevant insights for anyone involved in mining operations. His message was simple but powerful: the more we understand the minerals we’re working with, the better we can protect the people and equipment working around them.
"The focus wasn’t just on hazards. It was on opportunity — to get ahead of issues before they happen, using the tools we already have."
When Rock Becomes Risk
One of the key takeaways was the way mineral structures can change during processing — whether through blasting, crushing, or stockpiling. Some rocks, especially those altered by hydrothermal activity, can break down into extremely fine, respirable particles that behave differently than expected.
Cook’s team is using scanning electron microscopy (SEM) and AI-supported particle analysis to understand how different rocks disintegrate, and what kinds of dust result from that. These techniques let us go beyond broad mineral categories like “silica” and instead understand the real behaviour of particles on-site.
Why this matters: Not all dust is the same, and in a region like Australia where geology varies from site to site, having a more detailed understanding can mean more targeted — and more effective — protections.
Smarter Tools for Safer Outcomes
Thanks to emerging technologies, we’re getting better at predicting how different rocks will behave when disturbed. That means we can plan dust controls, cabin environments, and maintenance schedules around real risk — not assumptions.
This type of science is particularly applicable to surface operations in areas like the Bowen Basin or Pilbara, where mining activity exposes a variety of geologies. Understanding the dust profile of each site helps in deploying the right filtration, monitoring, and response systems.
What We’re Seeing on the Ground
At NB Industries, we support a wide range of clients across regional Queensland and other key mining hubs. What we’re seeing is a growing interest in predictive, real-time monitoring — not to tick a box, but because it helps keep operations running smoother and safer.
We’ve worked on sites where HVAC systems clog frequently due to unexpected particulate loads, or where cabin pressure fluctuates in ways that affect operator comfort and visibility. These aren’t isolated problems — they’re tied to the geology of the site and how materials break down.
And we’re finding that when teams have the right data, they’re able to act sooner, respond faster, and reduce disruption.
Local Experience, Global Insight
While Professor Cook’s work is rooted in Australian conditions, the conversation is clearly global. The ICMM continues to push for industry-led innovation in dust management, and Geoscience Australia is mapping mineral behaviours that could influence safety and performance.
The key is making sure this insight doesn’t stay in the lab. We need to keep connecting science, technology, and operational know-how to create real-world solutions that work — not just in theory, but on haul roads, at dig faces, and around machinery.
Final Thought: Turning Challenge into Opportunity
Professor Cook’s talk reminded us that the biggest risks aren’t always visible — but with the right knowledge, they’re manageable.
At NB Industries, we see this not as a compliance issue, but as an opportunity to support better, safer, more sustainable operations. It’s not about more layers of control — it’s about using the right tools in the right places, guided by smart insights.
We’re proud to work alongside teams across the sector who want to get ahead of the dust curve, not get caught in it. And the more we learn, the better we all get at keeping our people safe and our machines performing.
Tools Putting These Insights to Work
For those curious about how these concepts translate on the ground, here are a few technologies currently supporting smarter dust control and air quality management in the field:
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Sy-Klone ISO 23875-compliant systems – Creating filtered, pressurised cabin environments tailored to Australian mining conditions.
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DustGuard™ – Optical sensing to detect harmful engine air contamination early, reducing wear and improving reliability.
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CabGuard™ – Real-time cabin monitoring for particulates, temperature, CO₂, humidity, and pressure — giving crews a clearer picture of in-cab conditions.
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SORBA.ai – A predictive analytics platform helping teams anticipate performance issues and plan maintenance before failures occur.
These systems don’t replace best practices — they help teams build on them with better timing, clearer data, and more control.
Citations & Further Reading
Exploring new ways to manage dust, improve air quality, or boost safety performance?
Whether you’re facing site-specific challenges or looking to implement smarter systems, we’re here to help. Get in touch to explore how we can work together.