Posted by Control Concepts USA on | Comments Off on What Materials Are Prone to Problems in Material Handling?
One of the most common problems in material handling is how to get material to flow properly. Many materials have a tendency to clump, cake, or interlock during storage or mixing. That can impact the entire production process, and lead to unnecessary costs and safety issues.
Types of material blocks
Some materials have cohesive properties that cause particles to stick together. This can lead to bridging or ratholing.
During bridging, the material forms an arch above the outlet of the silo or hopper. The particles interlock and bond together because of cohesive strength and internal friction, while the wall friction holds up the ends of the arch.
During ratholing, the material adheres to the container sides, so the flow is limited to just above the container outlet. As more material flows through and accumulates on the walls, the block becomes bigger and more compact.
Bridging and ratholing can lead to all sorts of problems with bulk material handling. It slows down production, causes material waste, and compromises the formula’s consistency and quality. And if workers have to clear the blocks manually—by hammering or even climbing down into silos or hoppers with pick axes—they’re at risk for injury and unnecessary exposure to the material.
Problematic powders
About 50% of manufactured materials use powders at some stage of production. However, many powders are cohesive, which means they have a tendency to cake or become compact under their own mass.
Food ingredients
Some powders like flour have “easy” flow properties; any chunks can be broken apart with gentle aeration. However, heavier powders like cocoa, lecithin, whey, milk, sugar and sweeteners, spices, or even binders and preservatives will form solid, rock-hard chunks.
The food industry also needs to achieve first in/first out flow to avoid stagnant material that can spoil, thus compromising the product’s safety and breaking strict regulations on sanitation and hygiene.
Spoiled material and off-spec batches need to be thrown away, and even a single “bad batch” that escapes quality control can lead to product recalls.
Pharmaceutical powders
An estimated 60% of pharmaceutical sales come from powder formulations such as tablets, capsules, sachets, or inhalable powders.
During processing, pharmaceutical powders will go through several phases where they are exposed to moisture and air. These environmental factors—and variables in properties like size, shape, and texture—affect the flow properties, density, compressibility, and permeability.
These can pose numerous problems in material handling that must be managed well to ensure product efficacy and safety. Pharmaceuticals rely on precise measurements and proportions of ingredients. Material blocks can ruin an entire batch, and lead to material waste or even product recalls.
Grain products
One of the most common problems in material handling arises when conveying grain products from storage silos or bins. The materials may have sat motionless for days or even weeks, and have settled and become more compact. So, their flow properties are very different from powders or granules in aerated samples.
Some examples of common grain products are cornstarch, wheat bran, polenta, tapioca, couscous, rice, and hops. These are used in the food, pet food, beverage, nutraceutical, cosmetic and biofuel industries.
Cement powders
Cement uses many types of powders, including limestone, chalk, glass powder, and steel slag powder (SSP). Sometimes, granite powder is used in place of sand.
These materials all have unique flow properties, and the challenges increase when they are mixed and become sticky, moist, and heavy. Many cement plants have issues with materials bridging over silos and hoppers, which can slow down production speed and vessel capacity by as much as 80%.
Chemical powders
Many industries use chemicals either as a main material, or as a binder, preservative, or enhancer. For example, rubber tire manufacturers use carbon black to improve durability and performance. Battery manufacturers use lithium chloride and carbonate.
These chemicals can cause problems in material handling if they have a high moisture content, or have high cohesive properties. Some materials like carbon black tend to fluidize, forming deposits along the conveyor lines and storage vessels. Since it does not dissolve in water and solvents, cleaning can be time-consuming and expensive.
AirSweep solves problems in material handling
Leading companies in different industries rely on AirSweep to prevent bridging, ratholing, and other problems in material handling. Each nozzle emits a high-pressure, high-volume, 360-degree burst of compressed air to lift and sweep stalled material back into the flow stream – clearing the way for higher factory and material handling efficiency.
Watch material flow videos to see how AirSweep can activate even the toughest materials, from heavy powders to sticky and moist solids
Read case studies on how companies have increased productivity and reduced costs after installing an AirSweep system
You can also contact us to get a personalized consultation on how AirSweep can solve the specific problems in material handling that you encounter in your plant.
Posted by Control Concepts USA on | Comments Off on Top Challenges for Material Handling in the Candy Industry
Life isn’t always sweet for the candy and confectionary industry. The industry works with many materials that are prone to bridging, ratholing, and material blocks. Without a good flow aid, production can stall and end up in a big, sticky mess. We will review the top challenges for material handling in the candy industry.
Most common challenges in material handling
Candy and confectionary can use many different materials, ranging from powders to oily or moist solids, small particles to large pieces of nuts, or brittle.
These materials have unique characteristics that can affect material flow and production.
Free flowing and non-free flowing powders. While some flow freely from the force of gravity, others have more cohesive properties and are prone to packing during storage, and bridging and ratholing during production.
Moist, oily, or sticky liquids and solids. These include raw materials like honey and end-products like caramel. Some materials have a tendency to cake and smear on vessel walls; others can crystallize or thicken under certain plant conditions, further inhibiting material flow.
Blends and mixes. These can have ingredients that are different sizes, shapes, and densities. Aside from sticking to the sides of the vessel, the mix can segregate and compromise batch uniformity.
Hygroscopic materials. These have a tendency to attract and retain moisture, which leads to clumping and caking during storage and mixing.
Corrosive materials. The food industry uses concentrated acids, chlorides, and chemicals like sodium bisulfite and sodium sulfite. Aside from this, the food industry uses hot steam and chemical solutions to clean vessels and meet sanitation standards. This highly caustic environment means that the vessels—and any attached material flow aids—have to be made of materials that resist corrosion.
Abrasive materials. Grains and hard crystals like polyols can wear down vessel walls.
Perishable materials. Almost all materials used in making confectionaries are easily spoiled and contaminated and need both careful handling and first-in/first-out material flow.
Best flow aid for the candy industry
AirSweep is the best flow aid for tough materials. The powerful air pulses can handle cohesive powders and even moist, oily, and sticky mixes. It is used by food manufacturers around the world, many of whom switched to AirSweep because it performed better than vibrators, fluidizers, and other flow aids.
R. M. Palmer, a candy manufacturer in Pennsylvania, produces specialty holiday confections for US and international distribution. It uses a fine cocoa powder with 12% oil content, which caused bridging and ratholing in the hoppers and required manual cleaning every three to four days.
After installing AirSweep, the plant went from downtime every 3 or 4 days to “no breakdowns, replacements, or any problems whatsoever.” They were even able to add two production shifts per month, increasing productivity and profit margins so much that they were able to recover the cost of the system in just two months.
“AirSweep works,” he said. “It has a stronger air pulse than the bin aerators or fluidizers we previously installed. The air moves the powder down in a very large column so powder doesn’t stick to the walls.”
5 benefits of AirSweep for the candy industry
AirSweep’s unique construction also makes it ideal for the unique conditions of the candy and confectionary industry.
Guaranteed on-demand, first-in / first-out flow prevents material stagnation and spoilage
USDA-accepted design meets the strictest standards for sanitary equipment
Air-tight nozzle snaps shut after each pulse, preventing fine powders and dust from entering the system
Durable finish resists abrasion and corrosion and can be safely cleaned with chemical agents
Fast and easy assembly allows the unit to be removed for cleaning without any special tools
Get a customized proposal for your process
AirSweep is used in thousands of plants around the world and has solved many challenges in material handling that other flow aids could not. Contact us to find out how you can improve your material flow.
Posted by Control Concepts USA on | Comments Off on AirSweep, DAZIC & AcoustiClean: Integrated Solutions for Bulk Product Handling
The production process involves several interconnected steps. Any problems in one stage often create a domino effect, causing more delays and incurring more costs. Control Concepts, Inc. offers proven bulk product handling technology that improves plant efficiency and productivity that can be used individually or integrated to reduce downtime, material waste, and safety hazards.
AirSweep for on-demand material flow
Poor material flow can lead to several problems that can affect a plant’s productivity and a company’s bottom line.
Lower productivity. When the flow stops, so does the entire production line.
Smaller vessel capacity. Stagnant material can reduce the amount of material that can flow in and out of the vessel.
Material spoilage and waste. Inconsistent material flow can lead to stagnant and spoiled material or inconsistent batches that need to be thrown away.
Worker safety hazards. Workers have to manually clear material from vessels and may be unnecessarily exposed to hazardous materials.
Prevent these problems with AirSweep. It releases powerful air pulses that push material into the flow stream, leading to steady, on-demand flow.
AirSweep is proven effective for materials with challenging flow properties, such as powders that tend to clump or moist and sticky mixes that stick to vessel walls.
Many customers say that AirSweep was the only flow aid that worked for them—they tried fluidizers, vibrators, and air cannons, but still had to manually clear material. But once they installed AirSweep, they never had to worry about material blocks again.
DAZIC for preventing material pile-up
Many processes involve moving tons of material at a time. If any of the equipment malfunctions, that could mean massive spillage—and a mountain of problems.
Days of downtime. Equipment must be turned off until the material pile-up is cleared. Workers have to manually clear the material, or sit around and wait until production resumes.
Material waste. In some cases, the material is too contaminated to reuse and must be thrown away.
Safety hazards. Workers may be exposed to toxic or hazardous materials.
DAZIC zero speed switches can help prevent material pileups and detect machine failure. They are attached to rotating shafts and send an alarm when there is an abnormal change in rotation speed.
DAZIC speed switches are affordable, efficient, and durable. Many clients are still using the switches they installed over a decade ago, and have never had any incidents of material pile-ups.
The speed switches can be installed on any equipment with a rotating shaft, such as rotary valves, bucket elevators, belt and screw conveyors, saw blades, and drive motors.
AcoustiClean for clearing powder build-up
Powder build-up can clog pipes and affect equipment efficiency, and even create potentially flammable environments. Manual cleaning takes too long, and may even be impractical or impossible for some plant set-ups.
AcoustiClean sonic horns can clear powder build-up quickly and easily—and will never damage even fragile equipment. It releases sound vibrations that can disperse particles even in blind spots that mechanical blowers and rapping systems miss.
Integrated solutions for maximum plant efficiency
AirSweep, DAZIC, and AcoustiClean can work together to control material flow, clean residue, and prevent build-up—as seen in this diagram of a co-gen plant.
Find the right bulk product handling system for your needs
Control Concepts, Inc. can customize a bulk product handling system for your particular material, vessel, and process. Contact us so we can discuss your needs and provide you with a customized diagram.
Posted by Control Concepts USA on | Comments Off on 3 Types of Material Blocks that Slow Down Production
In the manufacturing process, production speed and product quality heavily depend on reliable material flow. That means materials flow smoothly, in a first in/first out pattern. However, bulk materials have a tendency to clump together, cling to vessel walls, or form large material blocks that restrict the discharge outlets. Flow can slow down, or even stop completely. Here are the most common types of material blocks, and the only flow aid you need to prevent them.
Bridging / arching
As the name implies, materials form a large bridge or arch right above the vessel outlet. This happens when the particles interlock and bond together, and need an external force to break it up and restore the flow.
There are two types of bridging or arching:
Interlocking arch. The particles mechanically interlock, like pieces of a jigsaw puzzle.
Cohesive arch. The particles are bonded together because of moisture, temperature, or the concentration of fines.
The strength of the bridge or the arch depends on the material’s inherent cohesive strength and the internal friction of the particles. For example, very fine powders like flour may respond to gentle aeration. However, cocoa powder or titanium dioxide—which has a tendency to clump and aggregate—will need more powerful, concentrated air pulses.
Ratholing
Ratholing occurs when materials accumulate along the vessel walls, leaving only a small flow channel right above the outlet. This creates two problems: the flow slows down, and stagnant material stays in the vessel. Without first in/first out flow, manufacturers run the risk of spoilage and contamination.
Furthermore, if the material has cohesive properties, it will cake and agglomerate instead of flowing out of the vessel. Eventually, the channel closes up and the flow completely stops.
Particle segregation
Granular materials can segregate because of differences in size, shape, and density. This can occur during crushing and grinding, transportation, storage, and mixing.
Segregation is especially critical in the chemical, pharmaceutical, and food industries when materials must be mixed in exact proportions to protect product integrity. For example, a supplement needs a precise balance of vitamins and minerals that is declared on the nutrition label—otherwise, the company could be slapped with a fine and be forced to recall entire batches that don’t meet the specs.
The “perfect” material flow
The gold standard of material flow is mass flow, which has the following characteristics:
Steady, uniform flow with a consistent bulk density
First in / first out – no stagnant material
Controlled discharge rates with no issues of stopping or flooding
AirSweep: achieve reliable material flow
AirSweep is a pneumatic flow aid. It uses powerful, 360-degree air pulses to break apart material blocks and sweep material back into the flow stream.
And when material flows, so do productivity and profits.
Reduce downtime from manually clearing material blocks or flushing vessels between product batches
Improve product consistency and quality by preventing stagnant material and segregation
Avoid material waste from throwing away contaminated material or inconsistent batches
AirSweep also lowers maintenance costs, because it uses less energy and does not damage vessels like other flow aids such as vibrators and fluidizers.
Get a customized proposal for your process
There is no “one size fits all” setup to prevent material blocks. We can customize an AirSweep system where nozzles are positioned at the right place, and release the right sequence of pulses, to move material efficiently.
Contact us to find out more about how AirSweep works, and how it can help improve your process.
Posted by Control Concepts USA on | Comments Off on Why is AirSweep Effective for Mined Materials?
Mined materials are one of the most critical components of the manufacturing industry. They are used to make thousands of commodities, from automobiles to electronics, and even medicines and household cleaning products. The mobile phone alone uses 42 different minerals—not including what is used for its packaging (paper and plastic need minerals, too!)
You can mine it… but can’t you move it?
However, mined materials have poor flow properties that can pose challenges during storage, processing, and packaging.
For example, hydrated lime—one of the most common components of cement production—is sluggish and has a tendency to pack, bridge, or rathole.
Wet materials such as damp sand or Diatomaceous earth can cling to vessel walls and plug the outlets.
Minerals with irregular particles can also segregate if they have a different hardness, grade, or size. Even after they are carefully screened and processed to a more consistent form, the particles can still interlock.
The best flow aid for mined materials
It’s important to choose a flow aid that can handle mined materials’ unique characteristics. Fluidizers can only activate powders that respond to light aeration. Vibrators can cause some minerals to become more compact. Air cannons still leave residue on vessel walls, and the air tends to “channel” through holes in the material, greatly diminishing effectiveness.
That’s why many companies switched to AirSweep. The powerful air pulses can improve the flow of any mined material—from fine powders to heavy rocks.
AirSweep increases productivity
A leading processor of industrial minerals handles more than 120,000 tons of material every year. However, their biggest challenge was transferring the processed material. It took over an hour to fill one supersack, and workers still had to hammer the vessels.
AirSweep cut that filling time from one hour to two minutes—a 3000% increase in productivity. Production volume increased to the point that an additional forklift driver was hired to keep up with the output.
AirSweep saves money
A cement company had issues with shale clogging the silos. They tried air knockers and vibrators, but workers still had to manually clear the vessels—losing $12,000 per hour of downtime.
AirSweep was the only flow aid that cleared all material build-up, and it used half the energy of air knockers. Since the cost per KWH was very high in their country, the electricity savings alone brought a great return on investment.
The proof is in the flow
AirSweep is used in thousands of plants around the world and has been proven effective for even the most problematic mined materials. Watch this material flow test on powdered hydrated lime.
AirSweep in the mined materials industry
Visit this page to find more case studies and videos on how AirSweep is being used to activate mined materials or contact us for more information and a customized quote.
Posted by Control Concepts USA on | Comments Off on 5 Top Technologies for Automated Bulk Material Handling
Bulk material handling is an essential part of any industrial or manufacturing process. Raw materials must be delivered to a factory, unloaded into storage facilities, and then poured into silos, hoppers, and other vessels for processing. Automated bulk material handling can make these processes more efficient. Here are some of the latest technology that can help move material in a faster, safer, and even cheaper way.
Automated guided vehicles (AGVs)
AGVs are self-propelled vehicles that can move large volumes of material along a defined pathway, like receiving to the warehouse or straight to the production lines. They can replace manually-operated forklifts and carts, or be used in areas that can’t be reached by conveyor systems.
The AGVs are guided by software and sensors. They can be programmed to run at specific times or stages during the production cycle so that materials are delivered whenever they are needed, without interruption.
There are many different kinds of AGVS: forklifts, carts, towing vehicles, and unit load handlers for small items.
Automated Storage & Retrieval System (AS/RS)
AS/RS systems handle, store, and retrieve materials in warehouses and other storage facilities. This can include automated carousels, vertical lifts, shuttles, and other machines that can lift heavy loads.
AS/RS can maximize storage space, reduce damage to products, and improve inventory control. Since fewer people are required to move items, companies can also tighten security and limit who can access the warehouse and other storage areas.
Warehouse Tracking
Warehouses need to follow a first in/first out system so that materials don’t spoil. However, new shipments are usually placed on top of the stack, so it’s hard to track where the oldest materials are.
Smart warehouse technology systems use coordinated routing, tracking, and control systems to show employees which box or bag must be used next. This includes a consolidated Warehouse Management System (WMS), automated picking tools, and automated inventory control platforms.
Aside from preventing spoilage, these new bulk material handling technologies reduce the cost of manpower and improve demand forecasting.
Machine Monitoring
Machine monitoring prevents shutdowns caused by machine failure.
Sensors alert operators of any problems in mixers, grinders, or conveyors. For example, the material got wet and stuck to the machine, or the scales malfunctioned and overloaded the vessel.
Sensors can also detect vibrations, unbalanced loads, and temperatures of the bearings. While it won’t be able to diagnose the problem, automated monitoring allows operators to troubleshoot and do preventive maintenance.
The sensors are actually required in industries that work with fine powders or other flammable materials that could be ignited by excessive friction in machine parts.
Some sensors have been around for more than a decade, and are proven effective in preventing plant accidents. DAZIC zero speed switches can be attached to conveyors, bucket elevators, and other equipment in a material conveyor system. It detects abnormal changes in speed that could lead to material pileup.
Material flow aids
Poor or irregular material flow slows down production and compromises batch consistency. Stagnant material can also lower the storage capacity of silos and hoppers and may deteriorate and spoil.
Traditionally, workers would have to manually clear material with hammers and pick-axes. However, modern material flow aids like AirSweep can prevent material blocks from occurring.
AirSweep releases powerful air pulses that move stagnant material back into the flow stream. It can be used during processing to ensure first-in / first-out flow, or after processing to flush the vessels clean before the next batch.
Here’s how the AirSweep system allows automated bulk material handling:
Contact us to find out more about AirSweep and other products that can improve your bulk material handling.
Posted by Control Concepts USA on | Comments Off on What Causes Material Bridging in Hoppers and How AirSweep Can Help
Material bridging in a hopper can slow down production and reduce bulk storage space. The stagnant material can spoil or become contaminated, and workers have to clear the vessel and throw out compromised batches.
What is material bridging?
Bridging is the material block that forms above the discharge outlet of a hopper, silo, or any bulk material handling equipment.
The bridge is caused by friction on the vessel walls which slows down the flow of material. Eventually, the material particles start to bind and interlock, until it partially or completely blocks the discharge outlet.
The bridge is so strong that it can support the weight of material above it. New material can condense the trapped material further and strengthen the bonds.
Types of bulk material bridging
Mechanical bridging. Particles mechanically interlock, like jigsaw puzzles. This usually happens for particles that are larger than 3mm.
Cohesive bridging. Particles compress until they bind together. This usually happens for smaller particles, especially those that attract moisture.
What causes material bridging in the hopper?
Material bridging can be caused by the hopper design, the bulk material’s flow properties, and the conditions in the plant.
Hopper Design
Ideally, the hopper design should reduce friction and encourage material flow. However, there is no one-size-fits-all solution. Solids and liquids behave differently, and materials have unique properties that can also vary in different conditions. These factors have to be considered while choosing the hopper’s angle, and the outlet’s shape and diameter.
Bulk Material Properties
Some bulk materials are simply more prone to bridging and arching. This includes:
Moist and sticky materials
Materials that tend to settle during storage
Materials with a high cohesive strength
Hygroscopic powders that attract moisture
Pellets that soften and form soft clumps
Fibers that can entangle
Irregular particles that can interlock
Heavy materials that can push down on stagnant material and cause it to compress
Plant Conditions
Fluctuating temperatures can affect the stress on the hopper walls and the material flow properties. Moisture in the air can cause materials to expand and compress. Gas in the air can also permeate through powders and fill empty spaces.
The best solution for material bridging in the hopper
Material flow aids solve bridging and other material blocks by breaking up the cohesive bonds in the bulk material. However, not all flow aids can do this safely or effectively.
Manual cleaning—where workers hammer the vessel or enter the hopper to clear the build-up with axes and shovels—is slow and dangerous. Some bulk materials release flammable or toxic gases during storage. Workers are also at risk for falls, sprains, health problems from direct exposure to the material, or being hit by falling material.
Vibrators can damage the vessel and can cause some materials to become more compact. Fluidizers can only activate light powders; air cannons are expensive and still leave material residue on walls.
AirSweep is the most cost-effective solution for material bridging in hoppers. It releases powerful air pulses that break up bridging and sweep stagnant material back into the flow stream.
AirSweep material flow engineers customize the system so the units are installed at key areas on the hopper to stimulate first-in/first-out flow. They select the right model for the bulk material and the vessel size. The AirSweep USDA-accepted model is also specially designed for sanitary applications like food, beverage, and pharmaceuticals.
The AirSweep material flow system is energy-efficient. It uses less air than air cannons, and the units pulse in sequence instead of running continuously like vibrators and fluidizers. The units also have a large area of activation and move more material with every pulse.
Posted by Control Concepts USA on | Comments Off on Solve Common Problems When Handling Bulk Materials
Every industry uses dry bulk materials—whether it be chemical powders, pellets, flakes, mined minerals, raw materials, food, additives, stabilizers, or preservatives.
Each of these materials has its own properties that can affect how they behave while being stored, transported, or processed. And when you’re dealing with tons of materials, the stakes become higher. Any problems will incur huge delays and costs.
Bulk material handling (BMH) equipment can help prevent dry bulk materials handling issues, and improve production efficiency. The right equipment can even help lower costs, and increase plant safety.
Control Concepts, Inc.: Your Partner in Bulk Material Handling
Since 1951, we have helped companies resolve dry bulk materials handling issues. The patented technologies are used in every industry: mining, cement, food, pharmaceuticals, chemicals, mined minerals, and more.
We offer three products for bulk material handling: AirSweep pneumatic flow aids, DAZIC zero speed switches, and AcoustiClean sonic horns. Each of them addresses particular dry bulk materials handling issues to prevent delays, unnecessary costs, and safety risks.
AirSweep for on-demand material flow
Poor material flow is one of the most common dry bulk materials handling issues—and the most problematic. Sluggish flow (or even no flow) can:
Slow down production
Compromise batch consistency
Cause contamination and spoilage
Lower vessel capacity
Increase material waste
Create flammable environments
AirSweep uses powerful air pulses that break up material blocks and sweep stagnant material back into the flow stream. Unlike other flow aids like vibrators and air cannons (or the old-fashioned method of hitting the vessel with a hammer), it does not cause metal fatigue.
AirSweep has been proven effective for all types of dry bulk materials, including damp powders, plastic flakes, fibers like tobacco, pellets, and irregular particles like mined materials. It also has lower energy and maintenance costs than other flow aids, and can easily be removed from the vessel for cleaning with simple tools.
DAZIC zero speed switch to prevent material pileup
If a conveyor belt or bucket elevator fails, tons of material can spill over and pile up. Workers will need days to clean it up, and companies will need to face production losses and additional manpower costs.
Spilled material can also create safety risks, especially if it is heavy, flammable, or classified as a toxic chemical. That is why OSHA and other safety organizations require plants to take precautionary measures for machine failure and spills.
DAZIC zero speed switches are very affordable but can prevent very expensive and dangerous material pileups. They are attached to equipment to detect any abnormal change in rotation speed. If the equipment speeds up, slows down, or stops completely, DAZIC sends a signal to the operator to shut it down.
DAZIC can be attached to any bulk material handling equipment with a rotating shaft, such as
Rotary valves
Bucket elevators
Belt, drag, and screw conveyors
Fans
Blowers
Saw blades
Drive motors
Mixers
Crushers
Agitators
Rolling mills
AcoustiClean Sonic Horns to clear light material buildup
Light powders can accumulate on surfaces and hard-to-reach areas. This can cause contamination issues, affect the efficiency of the vessel, or create potentially flammable environments.
AcoustiClean Sonic Horns produce high-energy, low-frequency sound vibrations that disperse dry material. Compressed air is applied to a sound generator, which vibrates a titanium diaphragm. The sound waves clear the material, to clean your material handling equipment.
AcoustiClean can be integrated into the system to automatically clean the surface between production runs. It reduces plant shutdowns, prevents cross-contamination during production, replaces dangerous and expensive manual cleaning, and improves energy/heat transfer efficiency and lifespan of machines.
Bulk Material Handling Solutions
AirSweep, DAZIC, and AcoustiClean can prevent many dry bulk materials handling issues. For more information, or to get a customized quote contact us.
Posted by Control Concepts USA on | Comments Off on AirSweep Solves Biggest Bulk Material Processing Challenges
Reliable material flow is critical for efficient bulk material processing. Material blocks slow down production and waste time and money. Stagnant material can also be contaminated or affect batch consistency.
So, the biggest challenge of bulk material processing is to achieve on-demand, first-in/first-out material flow. Unfortunately, that is easier said than done.
Why is it hard to achieve reliable material flow?
There is no single, simple formula for achieving good material flow. You have to consider many factors, some of which cannot be controlled or changed.
Some materials have problematic flow patterns, because of their chemical or molecular structure, weight, and how they react to moisture.
Cohesive and adhesive force, which cause particles to stick together and block the discharge
Cohesive strength and internal friction affect how strong the material block is
Bulk density, which affects how easily it flows because of gravity
Particle size and shape
Tendency to absorb moisture
Angle of repose, which is directly related to the flow rate
Flow patterns are difficult to predict. Product formulas will include a variety of materials, which all have their own particle characteristics and densities. If a company decides to change its formula it can encounter a material flow problem.
Some vessels are not designed for efficient material flow. The slope or angle of the vessel and the size and shape of the discharge outlet can affect the rate of flow. Unfortunately, not all equipment is customized for the flow properties of the materials.
Plant humidity and moisture can affect materials. This is especially true for countries with high humidity or materials that are hygroscopic or have a tendency to attract moisture.
Material flow problems can occur at any stage of bulk material processing. Some materials can settle and become compact during storage, while others will flow well until it is mixed with other materials.
What are the most common material flow problems?
The most common bulk material processing problems are bridging, ratholing, and segregation.
Bridging occurs when material forms a large arch above the vessel discharge and stops the material flow. It can be caused by large particles interlocking, or smaller particles bonding together because of the moisture, temperature, particle shape, or concentration of fines.
Ratholing occurs when stagnant material builds up on the vessel walls and thus restricting the passage of materials. Aside from slowing down the flow, it also causes material waste and possible contamination.
Segregation is the uneven distribution of components of bulk material because of differences in their physical or chemical properties. This can lead to inconsistent formulas, which can affect product quality and safety.
What can improve material for bulk material processing?
AirSweep eliminates bridging, ratholing, material segregation, and other flow problems. It guarantees on-demand, first in/first out flow, and has lower energy and maintenance costs than other flow aids.
Posted by Control Concepts USA on | Comments Off on Benefits of AcoustiClean Sonic Horns
AcoustiClean Sonic Horns provide several material flow benefits that plant managers need. AcoustiClean Sonic Horns produce high-energy, low-frequency sound vibrations that disperse dry material. It can help clean vessels and equipment like silos, hoppers, heaters, and fans to minimize downtime and material build-up.
Sonic horns are often used in industries like cement, petrochemical, and power generation. However, it can benefit any process where material build-up can occur.
AcoustiClean reaches blind spots
Manual cleaning can be tedious, time-consuming, or even impossible in inaccessible areas. AcoustiClean’s powerful sound vibrations can clear out material in seconds, even in equipment that is hard to clean (i.e, pipes or baghouses) or are in hard-to-reach locations. It can also reach blind spots that mechanical soot blowers and rapping systems often miss.
No equipment damage
Unlike other cleaning systems that use pressurized air, sound vibrations don’t damage sensitive equipment like tubes.
Customizable for different environments
AcoustiClean can be made of either stainless steel or cast iron. Stainless steel can be sanitized easily and is suitable for food and sanitary applications. Cast iron can withstand temperatures up to 2000ºF.
A manufacturer of building materials sends waste materials like wood flakes and wet bark to a boiler furnace. However, the soot build-up affected the boiler’s heat transfer efficiency and clogged the equipment.
They tried installing soot blowers, but these melted in the furnace’s high temperatures. The pressurized air also damaged the tubes, further adding to their equipment costs.
The manufacturer replaced soot blowers with AcoustiClean Sonic Horns and saw instant results. With the soot removed, the furnace temperatures remained steady and allowed optimum production time.
AcoustiClean is Versatile
AcoustiClean Sonic Horns can be mounted and hung on practically any kind of equipment.
Silos
Hoppers
Boilers
Cyclones
Baghouse Filters
Super Heaters
Air Heaters
Economizers
ID Fans
ESPs
Ducting
SCRs
Low Maintenance
The AcoustiClean system is designed to be efficient and very easy to maintain. The only parts that need to be replaced are the sound generators (every few years) and the titanium diaphragm (the only moving part, which is replaced yearly).
Contact us for more information about AcoustiClean Sonic horns, and how they can benefit your plant operations.
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