OPERATIONAL ENVIRONMENTAL CONTROL
KEEP IT MOVING.
KEEP IT DOWN.
ZIRCON INDUSTRIES · LIQUID HEAT · LATEX 100
Cold weather stops conveyor belts. Airborne dust creates compliance exposure. Neither failure is mechanical — but both cost production hours and carry real consequences. Kelley Industrial represents Zircon Industries, a specialty chemical manufacturer with over 40 years of field-proven formulations for exactly these two operational problems. Liquid Heat prevents ice formation down to −60°F. Latex 100 locks airborne particulate at the surface before it goes anywhere.
Quick Specifications
CAPABILITY
Zircon Industries
IN MARKET
40+ years field-proven formulations
PRODUCT 1
Liquid Heat — Freeze Control
LOW TEMP RATING
Effective to −60°F
APPROVALS
OSHA · EPA · Goodyear Belting
PRODUCT 2
Latex 100 — Dust Control
APPLICATION
Latex 100 — Dust Control
QUOTE
Call 440.478.2922
ANTI-ICING
DEICING
FREEZE PROTECTION
STOCKPILE DUST SUPRRESION
AUTOMATED SPRAY SYSTEMS
OSHA/EPA APPROVED
PLC-CONTROLLED APPLICATION
⚠ FROZEN CONVEYOR OR DUST COMPLIANCE ISSUES? WE CAN RESPOND FAST.
OPERATIONAL OVERIVEW
TWO PROBLEMS.
ONE PARTNER.
Cold weather and airborne particulate are environmental problems, not equipment problems. But they shut down equipment all the same. A frozen conveyor belt costs the same production hours as a mechanical failure, and it’s often harder to explain to leadership because the fix looks simple — until it happens again in the next cold snap.
Airborne coal dust, aggregate fines, and mineral particulate create a different category of exposure: environmental compliance. When fugitive dust crosses a fence line or triggers a permit exceedance, the consequences are regulatory, not just operational. Water suppression works until it doesn’t — inconsistent coverage, freezing conditions, and surface disturbance from handling operations all create gaps.
Zircon Industries has engineered targeted chemical formulations for both problems. Liquid Heat addresses freeze control at the conveying system level — preventing ice formation proactively rather than reacting to it after the belt is locked up. Latex 100 addresses fugitive dust at the surface level — creating a durable film that holds particulate in place without continuous water suppression.
Kelley Industrial represents Zircon across the Midwest. We evaluate your operation, recommend the right product and application method, and coordinate delivery and application system support where needed.
INDUSTRIES WE SERVE WITH ZIRCON
· POWER GENERATION – COAL HANDLING & ASH SYSTEMS
· AGGREGATE & CRUSHED STONE OPERATIONS
· CEMENT & CONCRETE PRODUCTION
· STEEL & METALS MANUFACTURING
· MINING – SURFACE & JNDERGROUND
· RECYCLING & MATERIAL RECOVERY
· RAIL & INTERMODAL FREIGHT
· HEAVY INDUSTRIAL MANUFACTURING
PRODUCT 01 – FREEZE CONTROL
LIQUID HEAT
ANTI-ICING & DEICING FOR CONVERYORS AND MATERIAL HANDLING
When temperatures drop below freezing, conveyor belts, rollers, idlers, chutes, and transfer points begin accumulating ice. Liquid Heat prevents that accumulation from forming — applied proactively to the conveying system before temperatures drop, it remains effective to −60°F. Originally developed for the power generation industry. Now standard across aggregates, cement, steel, mining, and rail.
VIEW LIQUID HEAT DETAILS→
PRODUCT 02 – DUST CONTROL
LATEX 100
STATIC DUST CONTROL SEALANT FOR BULK MATERIAL STOCKPLIES AND SURFACES
When temperatures drop below freezing, conveyor belts, rollers, idlers, chutes, and transfer points begin accumulating ice. Liquid Heat prevents that accumulation from forming — applied proactively to the conveying system before temperatures drop, it remains effective to −60°F. Originally developed for the power generation industry. Now standard across aggregates, cement, steel, mining, and rail.
VIEW LATEX 100 DETAILS→
-60°F
LIQUID HEAT EFFECTIVE TEMPERATURE – WHERE OTHER PRODUCTS STOP WORKING
40+
YEARS ZIRCON FORMULATIONS HAVE BEEN FIELD-PROVEN IN DEMANDING OPERATIONS
0
CONTINUOUS WATER REQUIRED – LATEX 100 HOLDS THE SURFACE WITHOUT SUPRESSION
PLC
AUTOMATED SPRAY SYSTEMS AVAILABLE – TEMPERATURE-SENSING, HANDS-OFF APPLICATION
ZIRCON LIQUID HEAT· ANTI-ICING & DEICING · CONVER & MATERIAL HANDLING
THE FREEZE PROBLEM
ICE DOESN’T ANNOUNCE ITSELF
UNTIL THE BELT IS ALREADY DOWN.
Most conveyor freeze problems start the same way. Temperatures drop overnight. Moisture from the environment, from the material being conveyed, or from the previous shift’s wet-down cycle saturates belting, rollers, idler frames, and transfer chute surfaces. By the time the first shift arrives, the belt is locked up or slipping under the frozen buildup.
The reactive approach — chipping, steaming, or waiting for the temperature to rise — costs production time and creates safety exposure from manual clearing in an energized system. Worse, it accomplishes nothing for the next cold night. The only durable solution is prevention: apply Liquid Heat to the conveying system before temperatures drop and keep it from freezing in the first place.
Liquid Heat is not a deicer in the traditional sense. It is an ice preventative formulated to remain effective at temperatures that cause glycol-based products to fail. Applied to belts, idlers, chutes, and transfer points as part of a routine maintenance cycle — or through an automated spray system — it eliminates the freeze cycle that maintenance teams deal with all winter.
WHERE FREEZE PROBLEMS OCCUR
· CONVEYOR BELT SURFACES – TOP AND RETURN SIDES
· IDLER ROLLS AND IDLER FRAMES
· TRANSFER CHUTES AND IMPACT ZONES
· HEAD AND TAIL PULLEYS
· MATERIAL BUILDUP AT TRANSFER POINTS
· RSKIRTING AND SEAL SYSTEMS
· TAKE-UP SYSTEMS AND GRAVITY TENSIONERS
· OUTDOOR STORAGE AND RECLAIM SYSTEMS
The typical pattern we see: A plant runs a reactive deicing program — heated enclosures, steam lances, manual clearing. Every cold snap costs 2–4 hours of downtime and creates an unplanned maintenance event. The aggregate cost over a winter season is significant, but it gets absorbed as “weather.” Liquid Heat applied proactively to the same system eliminates most of those events, and the cost differential is not close.
LIQUID HEAT – KEY ATTRIBUTES
ELIMINATE ICE BEFORE IT FORMS
Liquid Heat is a preventative, not a reactive product. The operating advantage comes from consistent proactive application — not emergency response after the system is already frozen.
01
PREVENTATIVE, NOT REACTIVE
Liquid Heat is engineered to prevent ice formation, not to remove it after the fact. Applied proactively to belts, rollers, idlers, chutes, and transfer points before temperatures drop, it eliminates the freeze cycle rather than responding to it. The operational shift from reactive deicing to preventative anti-icing is the primary value of the product — it replaces emergency labor and unplanned downtime with a scheduled maintenance application.
02
-60°F EFFECTIVE TEMPERATURE
Most glycol-based freeze control products become ineffective below −20°F to −30°F. Liquid Heat maintains its freeze-prevention performance to −60°F — covering the full range of winter operating conditions across the Midwest and northern operating environments where other products stop working. For operations in extreme cold climates, this is not a marginal advantage. It is the difference between a product that works all winter and one that fails on the coldest nights.
03
CONVEYOR-SAFE FORMULATION
Liquid Heat is approved for use by Goodyear Belting and formulated with OSHA and EPA approved ingredients. It does not attack or degrade conveyor belting, rubber components, or steel structures — a concern with many aggressive deicing chemicals that accelerate corrosion and belt deterioration. The formulation is designed for direct application to the conveying system without the secondary damage costs that aggressive deicer chemistries create over a season of use.
04
AUTOMATED SPRAY SYSTEMS
For high-volume operations or systems where manual application is not practical, Zircon offers PLC-controlled, temperature-sensing automated spray systems. The system activates when ambient temperature drops to a set point, applies Liquid Heat to the conveying system, and shuts off when temperatures recover — without operator intervention. Automated systems eliminate the human factor in preventative application and ensure consistent coverage regardless of shift schedule or operational priority conflicts.
TEMPERATURE RATING
-60°F
Effective to −60°F — maintains performance where glycol-based products fail
REGULATORY STATUS
OSHA/ EPA
Formulated with OSHA and EPA approved ingredients. Approved for use by Goodyear Belting.
APPLICATION METHOD
Manual or Auto
Hand application or PLC-controlled automated spray systems — temperature-sensing, hands-off operation
LIQUID HEAT APPLICATION
WHERE IT GETS USED
PRIMARY APPLICATION
POWER GENERATION – COAL HANDLING
Liquid Heat was originally developed for the power generation industry. Coal handling conveyors from unloading to bunker transfer operate outdoors in winter conditions with wet, high-moisture material that creates ideal freeze conditions. Application to belt surfaces, transfer chutes, and sampling equipment keeps coal handling systems operational through extended cold periods.
PRIMARY APPLICATION
AGGREGATE & CRUSHED STONE
Aggregate conveying systems operate year-round regardless of weather. Belt freeze, frozen material buildup at transfer chutes, and ice on screen decks create both production loss and safety exposure. Liquid Heat applied to the conveying system and screen equipment prevents freeze buildup without disrupting production schedules or requiring equipment shutdown for clearing.
PRIMARY APPLICATION
STEEL & METALS MANUFACTURING
Raw material handling — ore, coke, limestone, and scrap — involves large-scale conveying systems exposed to winter conditions. Material freeze in transfer points, frozen belt return runs, and ice accumulation on structures adjacent to wet processing operations all create maintenance demands that Liquid Heat eliminates through proactive application.
APPLICATION
CEMENT & CONCRETE PRODUCTION
Limestone, clinker, and raw material conveying at cement plants operates continuously. Freeze events at transfer points and on outdoor belt runs create unplanned maintenance and production losses. Liquid Heat applied to outdoor conveying systems prevents the freeze cycles that disrupt continuous production operations.
APPLICATION
MINING OPERATIONS
Surface mining operations with open-pit conveyors and truck dump systems face extended exposure to freezing temperatures. High-moisture ore and overburden materials create severe freeze conditions at transfer points. Liquid Heat prevents material freeze on conveying equipment and reduces the labor cost of manual clearing on remote system segments.
APPLICATION
RAIL & INTERMODAL
Railcar unloading operations — rotary dumpers, vibrating discharge equipment, and receiving conveyors — face frozen material in cars and on conveying equipment simultaneously. Liquid Heat applied to receiving conveying systems keeps the unloading chain operational during cold snaps when frozen material already creates enough complications.
LATEX 100 MATERIAL HANDLING & DUST SUPPRESION
THE DUST PROBLEM
WATER SUPPRESSION WORKS
UNTIL THE WIND PICKS UP.
Water suppression is the default dust control method for coal piles, aggregate stockpiles, and bulk material storage surfaces. It works intermittently — and that intermittent performance is the problem. Wind events, traffic disturbing the surface, and the inevitable lapses in application coverage all create fugitive dust events. In regulated environments, a single significant dust event can generate enforcement attention that ongoing minor exceedances did not.
Continuous water suppression also has real operational costs: water consumption, application labor, frozen suppression systems in winter, and the ongoing attention required to maintain coverage. In many operations, dust control competes with other maintenance priorities and loses.
Latex 100 replaces the continuous suppression cycle with a surface treatment. Applied to the stockpile or storage surface, it penetrates into the material and creates a durable film that binds particulate in place. The surface resists wind disturbance and minor handling operations without the need for continuous reapplication. It is a targeted solution for operations where water suppression is not delivering consistent compliance performance.
WHERE FUGITIVE DUST CREATES EXPOSURE
· COAL PILE SURFACES AND RECLAIM AREAS
· AGGREGATE AND CRUSHED STONE STOCKPILES
· LIMESTONE AND MINERAL STORAGE
· FLY ASH AND BOTTOM ASH IMPOUDMENTS
· MINE TAILINGS AND OVERBURDEN STORAGE
· DISTRIBUTED SOIL AND CONSTRUCTION MATERIAL AREAS
· RAIL CAR UNLOADING AND STORAGE AREAS
· TRUCK TRAFFIC SURFACES ADJACENT TO STOCKPLIES
The compliance exposure pattern: Operations running water suppression typically have a plan that works on paper and doesn’t hold in practice — seasonal gaps when suppression systems freeze, labor gaps when application doesn’t keep pace with handling operations, and coverage gaps on the downwind side of large stockpiles. Latex 100 addresses the fundamental problem with water suppression: it can’t be there all the time. A treated surface can.
LATEX 100 – KEY ATTRIBUTES
LOCK THE SURFACE. STOP THE DUST
Latex 100 is a static dust control sealant — not a suppressant. The distinction matters. Suppressants require continuous reapplication. Latex 100 binds the surface and holds it, reducing the frequency and cost of ongoing dust control operations.
01
SURFACE BINDING – NOT SUPPRESSION
Latex 100 works through surface penetration and film formation rather than moisture suppression. Applied to a coal pile, aggregate stockpile, or bulk material surface, it migrates into the top layer of material and binds particulate together as the carrier evaporates. The resulting surface film resists wind disturbance and minor handling operations without requiring continuous reapplication. It treats the surface — rather than wetting it — which is why it continues to function as surface moisture evaporates.
02
COMPLIANCE-DRIVEN PERFORMANCE
Latex 100 is specified by operations facing regulatory pressure on fugitive dust emissions — particularly in coal handling, aggregate processing, and heavy industrial material storage where airborne particulate creates permit exposure. The durable surface film provides consistent performance between application cycles rather than the intermittent coverage water suppression delivers. For operations that have already received dust-related enforcement attention, Latex 100 reduces the gap between what the compliance plan promises and what field conditions produce.
03
REDUCED WATER DEPENDENCY
Water suppression systems require water infrastructure, application equipment, operational labor, and maintenance — and they freeze in winter. Latex 100 reduces dependence on continuous water suppression by providing residual dust control between application cycles. In operations where water supply is constrained or suppression system maintenance creates coverage gaps, Latex 100 provides a cost-effective alternative to expanding water suppression capacity. It can also supplement water suppression on high-exposure surface areas where performance gaps create the most compliance risk.
04
TARGETED APPLICATION
Latex 100 is applied by spray — typically diluted with water and applied using standard spray application equipment. Application is targeted to the surface areas with the highest fugitive dust potential: pile crowns, windward faces, and active reclaim areas. Because Latex 100 creates a residual treatment rather than requiring continuous coverage, application resources can be concentrated on the highest-risk surface areas rather than distributed across the entire storage footprint in continuous cycles.
PRODUCT TYPE
Static Sealant
Film-forming surface sealant — not a suppressant. Residual performance between application cycles.
PRIMARY MATERIALS
Coal · Agg · Minerals
Coal piles, aggregate and crushed stone, limestone, fly ash, mine tailings, and general bulk material stockpiles.
APPLICATION
Spray – Diluted
Applied by spray with standard equipment. Diluted with water per Zircon specifications for the specific material and surface condition.
LIQUID HEAT APPLICATION
WHERE IT GETS USED
PRIMARY APPLICATION
COAL HANDLING – PILE & TRANSFER AREAS
Coal pile surfaces, reclaim areas, and active transfer zones generate fugitive coal dust under wind and handling conditions. Latex 100 applied to pile surfaces and high-exposure areas provides residual dust control between application cycles — reducing the continuous water suppression demand and closing the compliance gaps that water suppression leaves on windy days.
PRIMARY APPLICATION
AGGREGATE STOCKPLIES
Crushed stone, sand, and gravel stockpiles at quarry operations, concrete plants, and distribution yards generate visible particulate under wind and traffic. In operations near residential areas or regulated boundaries, that particulate is a complaint and compliance risk. Latex 100 treated surfaces hold fines in place under normal wind conditions and reduce visible dust from active stockpile areas.
PRIMARY APPLICATION
POWER GENERATION – ASH HANDLING
Fly ash and bottom ash storage presents a significant fugitive dust challenge — fine particle size, dry surface conditions, and regulatory scrutiny combine to make conventional suppression difficult to maintain consistently. Latex 100 applied to ash storage surfaces provides a surface treatment that holds fine ash particles and reduces airborne migration under wind and surface disturbance.
APPLICATION
MINERAL & INDUSTRIAL MATERIAL STORAGE
Limestone, cement clinker, potash, and other industrial mineral storage surfaces generate fine particulate under wind exposure. Latex 100 provides surface treatment for bulk mineral storage areas where particle size and surface conditions create fugitive dust exposure beyond what water suppression addresses consistently.
APPLICATION
MINE TAILINGS & DISTRIBUTED SURFACES
Mine tailings impoundments and disturbed surface areas at active mining operations create large-area dust exposure that is impractical to suppress with continuous water application. Latex 100 applied to high-exposure surface areas reduces airborne migration from tailings and disturbed ground during dry, windy conditions when compliance risk is highest.
APPLICATION
RAIL UNLOADING & RECEIVING AREAS
Active material receiving areas at rail unloading facilities generate significant dust during car dumping and transfer operations. Between active unloading events, Latex 100 applied to receiving areas and adjacent surfaces holds residual fines and reduces ambient particulate in areas where continuous suppression is impractical during active unloading operations.
01
DESCRIBE THE OPERATION
Tell us what you’re conveying, where it’s freezing, or what’s going airborne. The material, the system layout, the current approach, and what’s not working about it.
02
WE EVALUATE THE APPLICATION
We determine which Zircon product applies, at what dilution rate, using what application method. Freeze control and dust control have different coverage requirements — we spec accordingly.
03
RECOMMEND & SPECIFY
Liquid Heat or Latex 100 — or both if the operation has both problems. Automated spray system or manual application. We specify the right approach for your system before product ships.
04
SUPPORT THE PROGRAM
We coordinate ongoing supply, application system support through Zircon, and program adjustments when operating conditions change. The goal is a program that runs, not a one-time product sale.
Bearing isolators, turnaround safety, and custom-engineered sealing for high-risk industrial operations in the midwest
CONTACT
Kelley Industrial Sales, Inc is based in Cleveland, Ohio.