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Understanding the
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Travis Haynam
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  1. 1. PowderBulkSolids.com The Source for Dry Processing and Bulk Handling Technology Official Publication of PowderShow.com Vol. 32, No. 9 • IN THIS ISSUEAUGUST 2014 Dust Collection System Investment Performing a lifecycle cost analysis is an overlooked step in evaluating a a dust collection system. Too often, focus is given to the purchase price of the equipment versus determining ongoing associated expenses. Read more on page 8 Dust Collection & Air Pollution Control Process dust and powders are controlled by the high-volume air cleaning offered by large-capacity dust collectors from Micro Air Clean Air Systems and its exclusive Roto-Pulse cartridge cleaning system. Read more on page 17 Pneumatic Conveying The J.D.B. Dense Flow pocket elbow is designed for use on pneumatic conveying pipelines, and is most effective when highly abrasive materials are being transported. Read more on page 20 Explosion Isolation Valve Fenwal-IEP Technologies has released the ProFlapPlusIII passive isolation valve that is fully compli- ant with the new NFPA 69-2014 dust accumulation monitoring, flap blade-locking, and process shutdown requirements. The ProFlapPlusIII is a passive isolation valve that self-closes by the pressure wave created by an explosion inside a vented dust collector and prevents flame propagation to upstream processes. The ProFlapPlusIII is ATEX certified for organic and inorganic dusts with KST values up to 300 bar.m/s for duct sizes ranging from 5 to 12 in. in diameter, and KST values up to 200 bar.m/s for duct sizes ranging from 14 to 40 in. in diameter. Fenwal-IEP Technologies, Marlborough, MA 855-793- 8407 www.IEPTechnologies.com Reinforced Plastic Hose As a light suction and blast hose, the Protape TPE 321 offers the benefits of a fabric- reinforced hose: durable, abrasion-proof, and highly flexible, light, and compress- ible. In this version, the new hose is ideally suited for applications from the transport of powdery solids, through to gaseous media and steam extraction. It is also particu- larly suitable for blowers and compressors. The plastic hose can be used in operating temperatures of up to 110°C (short-term up to 125°C). It features small bend- ing radii and is kink-proof. The suction and blast hose is generally tape boxed and compressed which saves delivery costs and ensures minimum storage space. Norres Schlauchtechnik GmbH, Gelsenkirchen, Germany +49 (0) 209 – 80000 www.norres.com Choosing Cartridge Dust Collector Filters for Processing Applications Page 14 ES467113_PB1408_001.pgs 07.18.2014 20:19 UBMblackyellowmagentacyan
  2. 2. BulkBusterTM Bulk Bag Unloader Bella® Twin Shaft Fluidized Zone Mixer Dyna-SlideTM High Precision Air-Activated Feeder Dense Phase Transporter, J-Series BagBuster® Bag Breaker/ Cruncher® Bag Compactor GYRO EXTM Bin Activating Feeder/ Discharger Blendcon® Air Blending Head Multi-Port Switch - Up to 15 positions Less degradation Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear. Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from a few hundred pounds to 400 tons per hour, over distances exceeding 5,000 feet. Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises. Cost effective Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation BULKBUSTER TM BULK BAG UNLOADER MANUAL HOSE SWITCH VIBRA-JET ® BIN AERATOR WEIGH HOPPER BELLA ® TWIN SHAFT FLUIDIZED ZONE MIXER TRANSPORTER CONVEYING LINE SWITCH RECEIVER BAGBUSTER ® BAG BREAKER BLENDCON ® SILO BLENDER BLENDCON® AIR BLENDING HEAD DYNA-SLIDE TM HIGH PRECISION AIR-ACTIVATED FEEDER GYRO TM BIN ACTIVATING FEEDER STORAGE SILO STORAGE SILO STORAGE SILO MODU-KLEEN ® BIN VENT FILTER BULK BAG The Smart Way to Unload, Convey, Weigh & Mix and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation. Write or call us today with your questions, or for detailed information on our system applications. Dynamic Air Inc. St. Paul, MN Phone +1 651 484-2900 www.dynamicair.com ES465186_PB1408_002_FP.pgs 07.15.2014 00:47 UBMblackyellowmagentacyan
  3. 3. Performance-Proven Construction Integrated Automation Visit: nbe-inc.com Call: 616.399.2220 Visit: nbe-inc.com Call: 616.399.2220 NATIONAL BULK EQUIPMENT NATIONAL BULK EQUIPMENT Agitator Hoppers Bag Dump Stations Bullk Bag Fillers Bulk Material Mixers Storage Bins & Hoppers Drum & Container Dischargers Bulk Bag Dischargers Agitator Hoppers Bag Dump Stations Bullk Bag Fillers Bulk Material Mixers Storage Bins & Hoppers Drum & Container Dischargers Bulk Bag Dischargers 8-inch cantilevered I-beam is joined to thick-wall structural support framework using continuous weld seams. Exceeds ASME B30.11-2004 standard for bag weights up to 4,000 lbs.; I-beam registers only .070” deflection at full hang weight capacity. 4,000 lb. Bag Capacity 508A or Class I, Div. 1 and 2 Groups A-D, F, and G System-wide process control, communication, sensing, and monitoring are automated to ensure accurate material feed rates and optimal line speeds. Control Multiple Process Functions from One HMI From construction to custom programming, NBE is a single- source provider of line-specific PLCs and HMIs; easily integrate legacy systems from Ethernet to PROFIBUS and more. UL Listed Panels Designed, Built by NBE Accountable from concept to completion; NBE 3D modeling, process flow planning, and factory acceptance testing ensure trouble-free start-up and optimal line performance. Process Flow Diagrams, P&IDs, Factory Acceptance Tests Operate loss-in-weight programs in batch or continuous mode directly from the bag with central monitoring, communication, and control to improve line efficiency and also reduce material waste. Any Rate, Any Material: Accurate, Automated Material Feed NBE automated bulk bag dischargers fully integrate with downstream processing, packaging, and material transfer systems to enable accurate material feeding, interlocking safety switches, and central systems control. Integrated and Automated Equipment and Controls 3.5-inch bore hydraulic cylinders power two ribbed bag conditioning platens to deliver 28,000 lbs. of force to break up and discharge even the most severely hardened material; well beyond the force of pneumatic bag impactor designs. 28,000 lbs. of Ram Force Two, 6-inch bore pneumatic cylinders drive each of two heavy gauge steel paddles into the bottom, and against the sides of the bag. Over 7 sq. ft of contact surface and a tapered paddle top reach 15º past vertical to aid material flow. 5,400 lbs. of Paddle Pressure The E3 bag spout interface encloses the bag spout and feed tube within a sealed containment cylinder. Material dusting is eliminated and material flow rate is increased through a taut, conical spout shape. Complete, Dust-free, High-speed Material Flow Thick-wall structural tubing and heavy gauge carbon or stainless steel sheet and plate extend process line life cycles and optimize system performance in harsh and sanitary environments. Application-specific Construction "There’s no doubt NBE equipment is built to perform. It’s been years since our system was installed and I have yet to do any troubleshooting. And, I’ve had no operator complaints; no complaints is a compliment." Jeff P., Global Transportation Industry "The material we process is extremely sticky and compressed in the bulk bags. We used to manually break it up. Now, the machine does all the work. Material conditioning and flow to our batch mixing is now totally automated." Jeff P., Global Transportation Industry ES465189_PB1408_003_FP.pgs 07.15.2014 00:48 UBMblackyellowmagentacyan
  4. 4. Inlet/Outlet Chemical Isolation OR OR Inlet Protection Designed to react within milliseconds of detecting an explosion, a chemical isolation system can be installed in either inlet and/or outlet ducting. The chemical isolation system creates a chemical barrier that suppresses the explosion within the ducting, reduces the propagation of flame through the ducting and minimizes pressure increases within connected process equipment. Vertical Plenum A plenum that is bolted to the dirty air section of the collector. The explosion vent is mounted to the top of the plenum which effectively transitions the pressure and flame fronts from a horizontal to a vertical configuration. A vertical configuration make it possible to explosion vent through a roof and/or direct the pressure and flame fronts to a safe location as outlined in NFPA standards. In most cases, ducting and weather hoods are required to be compliant with NFPA standards to protect the explosion vents from the elements and other debris. Access panels are provided on the ducting so that easy inspection and/or replacement of the explosion vent is made possible without removing the ducting and weather hood. CHEMICAL ISOLATION EXPLOSION VENT DETECT & SUPPRESS AND MORE Explosion Venting Sequence 1 2 3 4 Fast-Acting Valve Designed to close within milliseconds of detecting an explosion, the fast-acting valve installs in either inlet and/or outlet ducting. The fast-acting valve creates a mechanical barrier within the ducting, which effectively isolates pressure and flame fronts (from either direction) from being able to propagate further through the process. Blast Plate A Blast Plate is a deflector mounted directly in front the explosion relief area. The deflector is designed to restrict the flame length ejected from the collector in the event of an explosion. For vessels that are not greater than 706 cubic feet, the deflector is designed to reduce the axial (front- centerline) safe distance by 50 percent. ES465192_PB1408_004_FP.pgs 07.15.2014 00:48 UBMblackyellowmagentacyan
  5. 5. Flameless Vent Designed to install over a standard explosion vent, the “FlamQuench SQ” extinguishes the flame front exiting the vented area not allowing it to exit the device. This allows conventional venting to be accomplished indoors where it could otherwise endanger personnel and/or ignite secondary explosions. Chemical Suppression Designed to react within milliseconds of detecting an explosion, a chemical suppression system is installed in the collectors dirty air section. The chemical suppression system prevents expanding a deflagration by releasing a chemical agent. This system is often used in order to put combustible dust collectors inside the factory where you can’t vent to the outside. Explosion Vent Designed to be the “weak” link of the vessel, explosion vents open when predetermined pressures are reached inside the dust collector allowing the overpressure and flame fronts to exit to a safe area. Explosion vents minimize damage to the dust collector caused by overpressure created by a deflagration. Camfil APC’s standard explosion vents are ATEX certified and NFPA compliant. The purpose of the Stinger is to prevent a deflagration (explosion) that could occur in the dust collector from traveling back down the inlet pipe back into the workspace/process. The iSMF has been proven to isolate the downstream equipment from the progres- sion of a flame front during an explosion. The Farr Gold Series® dust collector with an integrated Safety Monitoring Filter allows you to recirculate exhaust air back into the work space when your dust is explosive. The key advantage of this device is that it prevents the transmission of explosive dust (fuel) from the collector. Integrated Safety Monitoring Filter Detect and Suppress These systems protect the dust collector from ignition sources such as sparks or embers. It detects them and activates a suppression system that extinguishes them before they reach the collector. OR OR (Patent Pending) Outlet Protection Explosion Venting AIR POLLUTION CONTROL NFPA COMPLIANT COMBUSTIBLE DUST COLLECTION SYSTEMS Isolation Flap Valve TM IT LOOKS LIKE A SAFE BECAUSE IT’S www.camfilapc.com888-964-9342 ES465193_PB1408_005_FP.pgs 07.15.2014 00:48 UBMblackyellowmagentacyan
  6. 6. Powder & Bulk Solids6 Editor’sChoice August2014 Mercury Intrusion Porosimeters Provide Advanced Performance and Safety In addition to offering speed, accu- racy, and a wide measurement range, mercury porosimetry also permits the calculation of numerous sample prop- erties such as pore size distributions, total pore volume, total pore surface area, median pore diameter, and sample densities (bulk and skeletal). Micromeritics’ AutoPore V Series mercury porosimeters can determine a broader pore size distribution more quickly and accurately than other methods. These instruments also include enhanced safety features and offer new data reduction and reporting choices that provide more information about pore geometry and fluid transport characteristics. The AutoPore V is available in two models to best match the require- ments of quality assurance and research labs. The AutoPore V 9620 has a pore size range of 500 to 0.003 micrometers with two high-pres- sure (60,000 psia maximum pressure) and four low-pressure analysis ports. The AutoPore V 9605 contains two high-pressure (33,000 psia maximum pressure) plus four low-pressure analysis ports measuring pore sizes from 500 down to 0.005 micrometers. Micromeritics Instrument Corp., Norcross, GA 770-709-7108 www.micromeritics.com Patented Bulk Bag Material Conditioner Discharging bulk bags containing material that has solidified, hardened, or agglomerated can cause serious operational bottlenecks. Conditioning and emptying bulk bags can be dangerous if the proper equipment is not utilized. This patented system utilizes hydraulically actuated, heavy wall tubular steel pivoting conditioning arms. Each conditioning arm features “v-shaped” tubular steel breaker profiles that safely and efficiently return solidified materials to a free-flowing state. The unit features a proprietary automated control package that eliminates operator variability and increases productivity. A powered rotary lift table allows complete material conditioning of the bulk bag on all sides, and top to bottom. The unit features an ultra-compact footprint and machine guarding for operator safety. Material Transfer & Storage Inc., Allegan, MI 800-836-7068 www.materialtransfer.com Silo Weight Monitoring and Control Scale-Tron Inc. announces a major upgrade of the SiloWeigh. Net inventory management and control system that moni- tors the weight of material in silos or vessels located across a very wide area. The information can be used to predict when deliveries will be necessary, even if the user is not aware of it, and allow appropriate action to be taken. For example, deliveries for the next day can be scheduled rather than react- ing to urgent phone calls. In addition, the system is claimed to eliminate shutdowns due to empty silos as well as overfill and its environmental consequences. Temperature compensated bolt-on strain-gauge sensors on the vessel’s legs or skirt send data via a digital transmitter at each vessel to the local area computer network, where graphical displays can be viewed on any computer. An overview shows all silos at the location and individual trend graphs can show the usage and refill patterns on any silo. Data is also transmitted via the Internet or, when Internet is not available, the cellular radio network, to the SiloWeigh.Net main database. This database allows data retrieval via a secure Internet site to show levels in all silos as well as trend graphs and alarm logs. Scale-Tron Inc., St. Laurent, QC, Canada 514-940-0337 www.siloweigh.net Ultra-Heavy-Duty Bulk Bag Filling System This new ultra-heavy-duty bulk bag fill- ing system palletizes and fills bulk bags with filter cake, aggregates, metal powders, abrasive minerals, dry chemical additives, and other difficult-to-handle bulk materials. The system integrates a Swing-Down bulk bag filler with a Flexicon pallet dispenser and powered chain conveyor, allowing safe, high-capacity filling of bulk bags of all popular sizes, including bags with wide- diameter spouts for passage of irregular materials. When a filling cycle is initiated by push button or contact closure, pallet dispenser forks lower the stack of pallets onto the chain conveyor, withdraw from the bottom pallet, and raise the remaining pallets, allowing the conveyor equipped with photoelectric eyes to move the dispensed pallet into position below the filling station. The bag connection frame of the Swing-Down fill head lowers and then pivots to a vertical position, allowing an operator at floor level to safely and quickly attach bag straps to automated latches, slide the bag spout over a wide-diameter inflatable spout seal, and press a spout seal inflation button. Flexicon Corp., Bethlehem, PA 888-353-9426 www.flexicon.com Dual-Use Packaging System PDC International Corp., a world leader in the development and manufacture of shrink sleeve applica- tors and sleeve labeling systems, has introduced the 65 Series Shrinksealer. The newly re-engineered 65 Series was developed for continuous production environments. The equipment is ideally suited for shrink sleeve labeling, which involves full-height body sleeve labels with primary graphics. Used this way, the sleeve label can extend over the cap, with a horizontal perforation for tamper evidence on jars, bottles, and other containers. The machinery also performs tamper evident banding around the upper portion of a container and its closure, and applies full-height safety seals for vitamins and similar products. The machine operates at 50 to 175 cpm (containers per minute) with maximum speeds dependent on package dimensions. Sleeve diameter range is .375 to 3.25 in. Sleeve height range is .625 to 8 in. PDC International Corp., Norwalk, CT 203-853-1516 www.pdc-corp.com ES465351_PB1408_006.pgs 07.15.2014 03:34 UBMblackyellowmagentacyan
  7. 7. ES465417_PB1408_007_FP.pgs 07.15.2014 04:10 UBMblackyellowmagentacyan
  8. 8. 8 August2014 IndustryInsight P Understanding the Long-Term Value of Dust Collection System Investments Travis Haynam trahay@uasinc.com Performing a lifecycle cost analysis is often an over- looked step in evaluating the purchase of a dust col- lection system. Too often, focus is given only to the initial purchase price of the equipment versus deter- mining the ongoing expenses associated with operat- ing and maintaining the system. Perhaps the reason for this approach is that many companies do not com- pletely understand the relationship between proper dust collection system design and configuration or its impact on operational costs. Many of those initial design decisions and configuration choices make the difference between an effective solution which is a sound return on investment or an inefficient system that drives up operational expenses. If not properly designed, the expenses to operate and maintain a poorly configured system will rapidly exceed the initial purchase price. The most expensive aspect of the dust collection system is the energy re- quired to operate the air moving device. Therefore, investments that minimize the horsepower requirement, such as reducing the required airflow volume and operating static pressure, will yield significant long-term savings. Some steps that will decrease the power requirement include having favorable inlet and outlet conditions or utilizing an airfoil fan wheel to allow the blower to op- erate more efficiently. Incorporating variable frequency drives (VFDs) is an ad- ditional investment that can significantly reduce the blower operating expense up to 30%. Implementing poor duct design practices or selecting less than ideal duct ma- terials will also negatively impact operating costs. For example, choosing to use long sections of spiral duct or flex duct versus smooth duct may save money on the initial material cost but long term, the additional friction added to the system will increase the static pressure loss requiring additional horsepower to maintain the desired performance. Upgrades to the hood design such as a flanged or bell mouth hood will result in improved contaminant capture while reducing system energy requirements. Most dust collection systems utilize a reverse pulse jet arrangement to clean filters and maintain system operating pressure. The associated energy costs of these compressed air systems are another important cost to consider. Taking steps to minimize cleaning frequency or choosing equipment which is more effective per cleaning cycle are essential for controlling ongoing costs. Incorporating an on-demand pressure controller that only cleans the filters as necessary is also a sound investment that can further reduce longer term oper- ating expenses. Choosing filter technology such as nanofiber that incorporates a surface loading layer which improves the effectiveness of a cleaning cycle will decrease the cleaning cycle frequency and lower maintenance costs. Considering the lifecycle costs of a dust collection system investment is es- sential in order to realize the full system value and maximize return on invest- ment. Working with specialists within the industry who understand the impact design can have on long term operating expenses as well as the value of prop- erly configuring the system to match the process and application requirements will yield significant savings over the life of the system. Travis Haynam is director of business development at United Air Specialists Inc. (Cincinnati). He has been providing UAS customers with dust, mist, and fume extrac- tion solutions for 13 years. Haynam holds a BS in mechanical engineering and an MBA, both from the University of Cincinnati. Travis Haynam www. .com For more Dust Collection articles, please visit our Dust Collection Equipment Zone at PowderBulkSolids.com Move your dry products safe and secure in these rugged, reusable containers. X No pallets to break X Cube out trailers— stack and nest X No liners—no mess X All-plastic— waterproof X Sturdy—fill, lift, tilt, dump safely X UN, FDA, USDA, 3-A compliant designs X Molded-in numbers, RFID tags, tamper- evident locks Call 800.829.4535 free quote and brochure. See video! So much stronger than cardboard boxes! ShipShapeContainers.comMeese Orbitron Dunne Co. Solutions to all of your equipment needs in the online Industry Master PowderBulkSolids.com Callthe Experts forallyoursolidsprocessing. Applications: $3,VÂ$JKHPLFDOV $UWL¿FLDO6ZHHWHQHUV %LRORJLFVÂDWDOVWV HUDPLFVÂKHPLFDOV RVPHWLFVÂ)RRG,QJUHGLHQWV +HUELFLGHVÂ0LQHUDOV 1XWUDFHXWLFDOVÂ3HVWLFLGHV 3KDUPDFHXWLFDOVÂ3LJPHQWV 3ROPHUVÂ3RZGHUHG0HWDOV 3URWHLQVÂ5HVLQVÂ9LWDPLQV Manufacturing Quality Process Systems Since 1911 ZZZSDXORDEEHFRPVDOHV#SDXORDEEHFRP Vacuum Drying Rota-Cone and V-Dryers Solids Mixing Rota-Cone and V-Blenders Ribbon Paddle Mixers Fluidizing Dual Shaft Mixers Sigma Mixers Extruders Size Reduction Ball Ceramic Lined Mills Milling Jars Jar Rolling Mills ES465416_PB1408_008.pgs 07.15.2014 04:10 UBMblackyellowmagentacyan
  9. 9. See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems FILLER FOR PALLET JACK BAG REMOVAL Low profile version of patented TWIN-CENTERPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options. BULK BAG FILLER USES PLANT SCALE Full length forklifting tubes allow positioning of this TWIN- CENTERPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls. FILLERS WITH AUTOMATED FEEDING SYSTEMS Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters to interface with optional overhead storage vessels. COMBINATION BULK BAG/DRUM FILLER Patented SWING-DOWN® filler features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums. PATENTED SWING- DOWN® FILLER Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations. CANTILEVERED REAR-POST FILLER Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system. BASIC FILLER FOR TIGHTEST BUDGETS A lighter-duty version of the economical TWIN-CENTERPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options. PATENTED TWIN- CENTERPOST™ FILLER Two heavy-gauge, on-center posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust. Numerous performance options. First filler to receive USDA acceptance. CC-0710 Fill one bulk bag per week or 20 per hour at the lowest cost per bag Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements USA sales@flexicon.com 1 888 FLEXICON ©2014 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world. *Patent(s) granted and/or pending. CHILE UK AUSTRALIA SINGAPORE SOUTH AFRICA +56 2 2415 1286 +44 (0)1227 374710 +61 (0)7 3879 4180 +65 6778 9225 +27 (0)41 453 1871 Dump bags, compact waste and convey material dust-free FLEXICON® Bag Dump System collects dust generated during manual dumping and compaction of bags, and conveys bulk material downstream. Reduces material waste and eliminates need to clean a remote dust collection site, while protecting workers and preventing plant contamination. Compact system integrates a receiving hopper and glove box, with a dust collector, bag compactor and flexible screw conveyor. High velocity vacuum fan draws dust away from the operator onto cartridge filters. Reverse-pulse filter cleaning system releases short blasts of compressed air inside the filters causing dust build- up to fall into the hopper, for efficient, continuous operation. Empty bulk material from drums dust-free TIP-TITE® Drum Dumper seals drum against a discharge cone, tips the drum, mates the cone against a gasketted connection, and discharges bulk material dust-free through a slide gate valve. The drum platform is raised by a single hydraulic cylinder, creating a dust- tight seal between the drum and discharge cone. A second hydraulic cylinder tips the platform-hood assembly and drum, stopping at dump angles of 45, 60 or 90 degrees with a motion-dampening feature. The cone mates with a gasketted inlet port fitted to receiving vessels or process equipment. Accommodates drums from 30 to 55 gal (114 to 208 liter). Convey material from bulk bags to storage vessels pneumatically FLEXICON® Self-Contained Bulk Bag Discharging System with integral Pneumatic Conveying System transfers material from bulk bags to bulk storage facilities at locations unable to receive material by rail or bulk truck. SPOUT-LOCK® clamp ring* and TELE-TUBE® telescoping tube contain dust and keep spout/bag taut, promoting complete discharge. Material flow is aided by FLOW- FLEXER® bag activators that raise and lower opposite bottom sides of the bag. Positive pressure pneumatic system moves material to a silo or other vessel. BAG-VAC® dust collector creates negative pressure in sealed system to collapse empty bags dust-free prior to retying and disconnection. Weigh batch and blend bulk solids automatically FLEXICON® Self-Contained, Auto- mated, Gain-In-Weight Batching System can be integrated with new or existing processes and conveyor systems, or supplied with Flexicon pneumatic or flexible screw conveyors to transport materials from any upstream source to any downstream destination. Controller starts/stops each conveyor or rotary airlock valve to weigh multiple ingredients in sequence, first at high feed rate, then at dribble feed rate prior to stopping material flow once the accurate batch weight has been reached. Automatically compensates for material-in- flight. Allows concurrent blending of the discharged batch and weighing of a subsequent batch for fast cycle times. Handle multiple jobs with mobile flexible screw conveyor FLEXICON® Mobile Flexible Screw Conveyor increases versatility while eliminating the cost of multiple units. A wide range of screws and tubes, motor drives, hoppers, flow promotion devices, sensors, controllers, and other specialized accessories, enables these conveyors to satisfy the most demanding and diverse end use requirements. Handles free- and non-free-flowing materials with no separation of blends. Enclosed conveyor tube prevents product and plant contamination. Models with tilt-down portable bases can fit through doorways while providing easy access for screw removal and wash down. All units available in carbon steel with durable finishes, and in stainless steel to industrial and sanitary standards. Condition material solidified in bulk bags BLOCK-BUSTER® Hydraulic Bulk Bag Conditioner loosens bulk material that has solidified during storage and shipment, enabling bulk bag unloaders to discharge it through bag spouts. Two hydraulic rams with contoured conditioning plates press opposing sides of bulk bags. The number and pressure of ram actuations, the height of the turntable, and the degree of rotation are user-programmable. Intended for bulk bags containing solidified chemical and food products that cannot be loosened efficiently by pneumatically actuated flow promotion devices integral to bulk bag unloaders. System controller and hydraulic pump can be mounted on safety cage exterior or remotely. Requires only an electrical power connection for operation. ES465573_PB1408_009_FP.pgs 07.15.2014 20:28 UBMblackyellowmagentacyan
  10. 10. 10 August2014 Online now at www.PowderBulkSolids.com Special Advertising SectionLatest Industry News Updated daily, this section includes the most recent news headlines from all aspects of the dry processing industry. Equipment Zones An easily searchable archive of exclusive articles, expert columns, equipment reviews, and news - grouped by equipment category. Web Exclusives PowderBulkSolids.com includes Web-exclusive articles and columns such as Powder Perspectives that cannot be found in the print edition of Powder Bulk Solids. Online Industry Master Find equipment and suppliers for virtually every category to meet your needs. Editorial Calendar and Media Kit Discover what equipment focuses and spotlights will be included in Powder Bulk Solids in 2014. Powder Show and Industry Event Information Find out about upcoming Powder Bulk Solids shows, as well as other industry-related events. Visit www.PowderShow.com for information about upcoming Powder Shows Explosion Venting/ Suppression Q A Answered by Expert Gerd Mayer, REMBE Inc. Q:We had a community college install a dust collection system inside a room next to their welding area. There are 32 welding stations and three grinding stations (with aluminum, carbon, and stainless steel dust) go into the collector. Can this collec- tor be inside without venting and what is the chance of fire or explosion? A:I see two questions here: first, can a dust collector be located inside under the cir- cumstances you describe and the answer, in theory, is yes. Please check NFPA Standard 484, that strongly prefers dust collectors be located outside for metal dust applications. However, ... For the rest of Gerd’s answer please visit http://pbs.canon-experts.com or click on the Ask the Experts link at www.PowderBulkSolids.com Gerd Mayer Nol-Tec Systems — your partner in handling success With Nol-Tec’s 30 year history of successful pneumatic conveying design, you can count on system improvements that won’t cause disruptions further down the line. Our customer-specifc collaboration ensures your design will blend fawlessly with your current processes, saving you time and reducing overhead costs. Reliable, robust processing — tailor-made for seamless integration „ Dense and dilute phase conveying, both vacuum and pressure „ Air Assist™ technology to keep materials fowing „ Computer controlled automation and process control for consistency „ Service throughout the lifecycle of your system sales@nol-tec.com www.nol-tec.com Call 651-780-8600 today to speak with an experienced systems application engineer. ES465382_PB1408_010.pgs 07.15.2014 04:01 UBMblackyellowmagentacyan
  11. 11. www.PowderBulkSolids.com 11 August2014 TechnologyReview Dust Collection Air Pollution Control ProductFocus High-Efficiency Baghouse Saves Energy Scientific Dust CollectorsÕ new cleaning nozzle provides an improvement in cleaning technology that achieves high performance even at lower compressed air levels. These levels can be as low as 80 psig. In addition, the baghouse design removes flow-restricting venturies, reducing the filtered air velocity and saving 2 in. WC on fan requirements. All baghouse manufacturing is done in-house. Scientific Dust Collectors, Alsip, IL 708-597-7090 www.scientificdustcollectors.com Industrial Vacuum Systems Hi-Vac offers flexibility with tech- nologically advanced portable, stationary, and lift vac models, all with varying ranges of horsepower and operational/safety features to meet any application. For hazard- ous material handing, explosion suppression and isolation vacuum systems are available that adhere to NFPA regulations. Hi-Vac Products, Marietta, OH 800-752-2400 www.hi-vacproducts.com Explosion Isolation Valve Protects Against Dust Collector Explosions Camfil Air Pollution Control offers the Stinger, an explosion isolation valve that isolates dust collector explosions to prevent a deflagra- tion from traveling back through the inlet pipe of the dust collec- tor into the workspace. Following extensive testing, the Stinger is the first U.S.-made explosion flap valve to be certified by an inde- pendent testing agency to comply with NFPA standards. It may be retrofitted onto most dust collec- tion systems and used with new or existing Farr Gold Series dust collectors where the risk of a com- bustible dust explosion exists. A key feature of the Stinger valve is a lightweight, patent-pending com- posite blade that reacts with high speed in the event of an explosion. It closes faster than heavier steel blades typically used for dust col- lector inlet protection. Camfil APC, Jonesboro, AR 800-479-6801 www.camfilapc.com Filtration expertise trusted over In the 20 years since we invented the technology, BHA PulsePleat® industrial ¿OWHUHOHPHQWVKDYHKHOSHGLPSURYHWKHHI¿FLHQFRIDLU¿OWUDWLRQVVWHPVWLPH DQGWLPHDJDLQ%SURPRWLQJEHWWHUDLUÀRZWKURXJKDVLQJOHSLHFHHOHPHQWRXU SURGXFWVFDSWXUH¿QHGXVWZLWKRXWLQFUHDVLQJRXUIRRWSULQW:LWKRYHUPLOOLRQ VROGDQGHDUVRI¿OWUDWLRQH[SHUWLVHEHKLQGHDFKRQH%+$3XOVH3OHDWLQGXVWULDO ¿OWHUHOHPHQWVSURYHWREHDVROLGLQYHVWPHQWIRUDEHWWHUEXVLQHVV +RZPXFKYDOXHFDQDQLQYHVWPHQWLQ%+$3XOVH3OHDWLQGXVWULDO¿OWHU HOHPHQWVDGGWRRXUFXUUHQWEDJKRXVH)LQGRXWZLWKRXU%DJKRXVH (QHUJ6DYLQJVDOFXODWRUDWBHA.com. %+$$OWDLU//$OOULJKWVUHVHUYHG%+$LVDUHJLVWHUHGWUDGHPDUNRI%+$$OWDLU// /$525LQGXVWULDODLUFRP_ ES465381_PB1408_011.pgs 07.15.2014 04:02 UBMblackyellowmagentacyan
  12. 12. Powder Bulk Solids12 August2014 TechnologyReview Dust Collection Air Pollution Control ProductFocus Circular Tank Dust Collectors Especially effective for dust prob- lems in drying, grinding, and conveying systems, Flex-Kleen CT Series dust collectors are designed to operate in process systems environments with minimum maintenance. Basic CT units are designed for two levels of pres- sure capability of 40 to 100 in. W.G. or 17 in. Hg. (pressure or vacuum). Single units handle from 50 to 50,000 cfm. Multiple unit systems can be supplied to handle any desired gas volume. CT col- lectors can also be furnished for high pressure (over 15 psig) or for extremely low vacuum require- ments. CECO Environmental, Wayne, PA 215-723-9300 www.mpeas.com Industrial Air Pollution Control Systems UAS offers a range of industrial air pollution control systems to meet the challenges of collecting harmful pollutants from processes involving powders and bulk solids. Included are cartridge dust col- lectors, cyclone collectors, bag/ media collectors, and extraction arms and hoods. These units help keep your employees and facilities healthy and safe while meeting federal, state, and local clean air standards. Systems are customiz- able to fit specific process, ap- plication, and facility needs. UAS also offers a complete line of replacement cartridge filters that are compatible with UAS systems as well as virtually every major brand of industrial air cleaning equipment. United Air Specialists Inc., Cincinnati, OH 800-252-4647 www.uasinc.com Bag Dump Station Collects Dust to One Micron Hapman’s bag dump station keeps material within the production cycle and prevents dust from escaping into the plant environment. Featuring a low-profile, the bag dump station provides an efficient method to minimize dust when introducing bagged products into a process. Its self-contained filtration system allows for 99.9% collection efficiency down to one micron. No external ducting or auxiliary fans are necessary. Hapman, Kalamazoo, MI 800-427-6260 www.hapman.com www.dustsuppressionhopper.com 1-800-557-4689 Solves Dust Fallout While Transferring Dry, Granular Goods. BEFORE AFTER DUST SUPPRESSION HOPPER EĞǁdŝŐĞƌŇĞdžΡsŽůƚďƵƐƚĞƌΡ,ŽƐĞ ĞƐŝŐŶĞĚĨŽƌ,ŝŐŚ^ƚĂƟĐ ƉƉůŝĐĂƟŽŶƐ EĞǁsŽůƚΡĂŶĚ sd ^Ρ^ĞƌŝĞƐ ;ĨĂďƌŝĐƌĞŝŶĨŽƌĐĞĚ ŚŽƐĞƐĞīĞĐƟǀĞůLJ ĚŝƐƐŝƉĂƚĞƐƚĂƟĐ ƚŽŐƌŽƵŶĚ ,ĞůƉƐƉƌĞǀĞŶƚƐƚĂƟĐďƵŝůĚ ƵƉĂŶĚƌĞĚƵĐĞƐƉŽƚĞŶƟĂů ĨŽƌĚĂŶŐĞƌŽƵƐĞůĞĐƚƌŽƐƚĂƟĐĚŝƐĐŚĂƌŐĞƐ ,ŽƐĞƚƵďĞŝƐĐŽŶƐƚƌƵĐƚĞĚĨƌŽŵŚŝŐŚůLJĂďƌĂƐŝŽŶ ƌĞƐŝƐƚĂŶƚĨŽŽĚŐƌĂĚĞƉŽůLJƵƌĞƚŚĂŶĞ 'ƌŽƵŶĚŝŶŐǁŝƌĞŝƐĞŶĐĂƉƐƵůĂƚĞĚŝŶƚŚĞƌŝŐŝĚWsŚĞůŝdž ǁŚŝĐŚƐĂĨĞůLJĞůŝŵŝŶĂƚĞƐƚŚĞƌŝƐŬŽĨĐŽŶƚĂŵŝŶĂƟŽŶ͘ /ĚĞĂůĂƉƉůŝĐĂƟŽŶƐ͖ƚƌĂŶƐĨĞƌŽĨƉŽǁĚĞƌƐ͕ƉĞůůĞƚƐĂŶĚ ŐƌĂŶƵůĂƌŵĂƚĞƌŝĂůƐ͘ Kuriyama of America, Inc. www.kuriyama.com tFNBJMTBMFT!LVSJZBNBDPN Ρ Ρ ES465377_PB1408_012.pgs 07.15.2014 04:01 UBMblackyellowmagentacyan
  13. 13. www.PowderBulkSolids.com 13 August2014 TechnologyReview Dust Collection Air Pollution Control ProductFocus Explosion, Spark, and Flame-Front Isolation Protecting processes from the risks of combustible dust explosions per NFPA standards usually requires isolation of interconnected enclo- sures and conveying to contain an explosion. This is certainly true with dust collection processes. The REMBE Exkop system pro- vides safe, economic, and easy explosion, spark, and flame-front isolation. The pinch valve protects interconnected equipment by high- speed closure that is triggered by a signal from a panel, a Q-Rohr-3, a Q Box II, or sensor. The Exkop system is easy for plant person- nel to test/reset and, in the event of a power outage, is fail safe. The Exkop system is also now ap- proved for use up to 300 Kst. REMBE Inc., Charlotte, NC 704-716-7022 www.rembe.us Bulk Bag Discharger with Dust Filtration System The Material Master bulk bag dis- charging system offers patented technology and features that maxi- mize production efficiency. The unit is constructed of 4-in. square structural carbon steel tube and includes the heavy-duty Flo-Master “breaker bar” bag massaging sys- tem for positive material flow, while the stainless steel bag spout access chamber allows optimal ac- cess to the bag discharge spout. Material Transfer Storage Inc., Allegan, MI 269-673-2125 www.materialtransfer.com Pleated Filters There is not a single pleated filter element that meets the demands for every application, or even a large group of applications. Variables include media, strappings, end cap materials, and manu- facturing techniques. The filter combinations are near infinite, yet getting it right is critical. When variables are misapplied, catastrophic failure will occur. Clarcor can help select a pleated filter for specific applications. Clarcor Industrial Air, Overland Park, KS 800-821-2222 www.BHA.com ES465376_PB1408_013.pgs 07.15.2014 04:01 UBMblackyellowmagentacyan
  14. 14. 14 August2014 TechnicalExclusive caption C Choosing Cartridge Dust Collector Filters for Processing Applications Cartridge dust collection systems are the preferred technology for most dry processing applications today, and there are many different pleated filter cartridges available for these collectors. As you face stricter air quality and combustible dust regulations, coupled with tighter internal cost controls, choos- ing and using the best dust collector filter for your process is more important than ever. Making an in- formed choice can improve your collector’s dust cap- ture efficiency and reliability while reducing energy and maintenance requirements. Types of Filter Media There are two basic categories of media commonly used in pleated cartridge filters. The choice is usu- ally driven by dust type, operating temperatures, and the level of moisture in the process. 1. Nonwoven cellulosic blend: This media is the most economical choice for dry dust collection ap- plications at operating temperatures up to 160°F. Sometimes the fibers will incorporate a coating that en- hances moisture resistance. However, cellulose media as a category are not as resistant to moisture as synthetic poly- ester. 2. Synthetic polyester me- dia or polyester-silicon blend: This lightweight, washable media can handle dry appli- cations with maximum oper- ating temperatures ranging from 180°F to 265°F. These filters are washable and can recover from a moisture ex- cursion but are not intended for wet applications. Either type of media can be treated with a layer of nano fibers that boosts the efficiency and yields other benefits as well. Nano filter technology has advanced in recent years, and the newest generation of nano fibers can perform well even in the most extreme conditions. When a layer of nano fibers is applied on top of the base media - whether cellulosic or polyester - the nano coating promotes surface loading of fine dust, preventing the dust from penetrating deeply into the filter’s base media. This translates into better dust re- lease during cleaning cycles and lower pressure drop readings through the life of the filter, which, in turn, promote longer filter life as well as energy savings. Standard and nano filter media can also be treated with compounds that deliver special performance properties. Flame-retardant media are treated with a chemical that provides fire retardant properties for use where there is a risk of fire or explosion. Companies involved in metalworking processes such as plasma and laser-cutting, grinding, or welding commonly use filters with flame-retardant media. Conductive or anti-static filters may be used where conveyed dusts generate static charges that require dissipation. Typically, static dissipation is achieved by impregnating a cellulose filter with a carbon coat- ing or a synthetic filter with an aluminized coating. Applications for these filters include fumed silica dust, plastic, PVC, or composite dusts, and carbon black/toner dusts. Cartridge filters with anti-static media can also be used in explosive dust applica- tions, making it possible to conform to NFPA re- quirements and lessen the risk of ignition sources due to static electricity charges. In combustible dust applications where the minimum ignition energy of the dust is below 3 millijoules (mJ), the NFPA requires the filters to be conductive, bonded, and grounded to the filter housing. Selection Tips Following are five tips that can further help you de- termine the best filter for your application: 1. Understand the different measures of filter effi- ciency and how to apply them. There are two meth- ods that dust collector filter manufacturers typically use to express filter efficiency. Gravimetric analysis is based on particle capture by weight: For example, filter efficiency might be stated as 99.995 percent on particles of 0.5 µm or larger by weight. Filter efficiency may also be expressed as a Minimum Efficiency Reporting Value, or MERV, based on a scale from 1 to 16, with MERV 16 being the highest efficiency. By Rick Kreczmer, Camfil APC Conductive (anti-static) filters may be used where conveyed dusts generate static charges requiring dissipation. ES466424_PB1408_014.pgs 07.16.2014 23:34 UBMblackyellowmagentacyan
  15. 15. www.PowderBulkSolids.com 15 August2014 The MERV scale was developed for the HVAC filter market and does not take into account the way a dust collector operates (i.e., it pulse-cleans filters periodically when a dust cake builds up). Though MERV and gravimetric efficiency ratings are useful tools for comparing filters, you should not rely on these measures alone to determine efficiency. It is more relevant to make sure you are satisfying OSHA or EPA re- quirements for filter performance – OSHA if you are discharging the air and recirculating it indoors downstream of the collector, the EPA if you are discharging the air outside or into the environment. Mass density efficiency, defined as the weight per unit volume of air, is the best predictor of a filter’s OSHA compliance. For example, OSHA might require that emissions will not exceed 5 mg/cu m at the discharge of the dust collector. Similarly, the EPA doesn’t care about percentage efficiency claims; they want to know that emissions will be at or below required thresholds, typi- cally stated as grains per cu ft or mg/cu m. Concerned about which effi- ciency measure(s) to use? If so, you are not alone. But there is a way to cut through the confusion and make sure your bases are covered: Require your filter sup- plier to provide a written guaran- tee of performance stating that the filters you select will satisfy applicable OSHA or EPA require- ments. It is worth noting here that ASHRAE is developing a new standard specifically for measur- ing performance of dust collector filters. Finalization of that stan- dard, however, is at least a couple of years away. 2. Test your dust. The collec- tion and testing of dust samples is a long-established practice used by processing professionals to make informed dust collection decisions. While dust testing has always been good practice, it is rapidly becoming a necessity in today’s regulatory climate. There are two types of dust testing: (1) bench testing, which pinpoints physical properties of the dust, and (2) explosibility test- ing, which determines whether a dust is combustible. Bench testing involves a series of tests that provide valuable data for filter selection. Particle size analysis reveals the dust’s par- ticle size distribution down to the submicron range to determine the filtration efficiency needed to meet emissions standards. This test pinpoints both the count (the number of particles of a given size) and the volume or mass spread of the dust. Knowing both is important because many dusts are mixed. A video microscope provides visual analysis of the dust shape and characteristics. Together with particle size analysis, this tool is vital for proper filter selection. For example, a microscope may be needed to detect oil in the dust. Moisture analysis equipment measures a dust’s moisture per- centage by weight, providing information that can prevent moisture problems. A humid- ity chamber is used to see how quickly a dust will absorb mois- ture. This helps to identify hy- groscopic (moisture-absorbent) dust which requires widely pleated filter cartridges, as these sticky dusts cause filters to plug. Additional bench tests can help to determine the optimal design of other dust collection system components. It is not necessary to bench-test dust 100 percent of the time, but if there is anything at all unusual about the process and/or the dust, it’s a good idea. To determine whether a dust is combustible, it should undergo separate explosibility testing as stated in NFPA Standard 68. If a dust sample is not available, it is permissible to use an equiva- lent dust (i.e., same particle size, etc.) in an equivalent application to determine combustibility. But once the dust becomes available, it is still recommended that you go back and test the dust using either the 20-l test method de- scribed in ASTM E1226-12a or the similar method described in ISO 6184/1. Using your dust sample, the lab will start with a screening test to determine whether the Bench testing identifies physical proper- ties of the dust, aiding filter selection. An engineered test is performed at an official testing facility to confirm that this dust collector can withstand an explo- sive event. Scan QR code to view brief explosion test video. ADVERTISEMENT Wear resistant pipe bends Jason Hunter, Pelletron Corporation Pneumatic conveying of abrasive materials wears out standard, long- radius pipe bends quickly. There are various types of pipe bends designed for extended lifetime available. Pelletron developed a special elbow that withstands the most abrasive materials. Wear problems are common in dilute phase conveying systems with high velocities. The conveyed product slides along the elbow wall at a high velocity and high centrifugal forces press the conveyed material against the outer metal surface. The resulting friction causes the elbow walls to wear out quickly. Pelletron developed a unique, patented conveying pipe elbow that is trade named the Pellbow®. It is especially designed to minimize damage caused when solid particles are injected into a high velocity con- veying system — the higher the velocity, the higher the friction. Using a Pellbow® avoids the problems caused by friction in traditional elbows. P PneumaPneuma radius prad us p designedesign specialspe By design, material flowing through the Pellbow® forms a pocket or “impact zone” and moves slowly upward and out. Incoming material is deflected at 90 degrees with minimum resistance and no impact damage. The Pellbow® is wear-resistant making it the ideal solution for conveying abrasive products. The Pellbow® is self-cleaning when the material flow is stopped and it works in all installation positions. Long-radius elbows or other types of pipe bends in existing vacuum and pressure dilute phase conveying systems can be easily retrofitted with the Pellbow®. The pressure drop compared to long-radius elbows is minimally higher. The minimum product-to-air ratio of 3:1 or higher guarantees best results. The Pellbow® is designed to fit all kinds of pipe and tube connections. The Pellbow® is available in aluminum, stainless steel and cast iron for pipe sizes from 1.5” up to 12”, as well as in surface hardened versions. More information is available at www.pelletroncorp.com Contact Pelletron to get a free-of-charge recommendation and a proposal for your application. Pelletron Corporation Tel.: 717.293.4008 Clear Pellbow® in operation Pellbow® model Wear resistant Pellbow® Re-accelleration Zone Slurry Primary Impact Zone Conveying Phase Transition Zone Bernoulli Step Incoming Material Standard long-radius pipe elbow To determine whether a dust is combustible, it should undergo separate explosibility testing as stated in NFPA Standard 68. ES466423_PB1408_015.pgs 07.16.2014 23:34 UBMblackyellowmagentacyan
  16. 16. Powder Bulk Solids16 TechnicalExclusive August2014 dust is combustible. If the dust is not combustible, testing will stop there. If it is combustible, the lab will conduct further testing on dust cloud parameters to pinpoint the Kst (defined as the deflagra- tion index of a dust cloud, or rate of pressure rise) and Pmax (the maximum pressure in a contained explosion). Explosibility testing is per- formed primarily to help deter- mine what explosion protection or prevention equipment is needed on your dust collector and related components. But it can also play a role in filter selection. For example, testing for the mini- mum ignition energy can help determine if conductive filters are needed. 3. Evaluate total cost of own- ership. When choosing between two cartridge filters with the same rated efficiency, some pro- cessors will regard these items as a commodity and simply choose the lowest-priced filter. But as with most purchasing de- cisions, initial cost is only one factor, and it requires a “Total Cost of Ownership” (TCO) evalu- ation to make the best filter se- lection. TCO helps you determine what it really costs to own your dust collector filters by calculating all the components of true filter cost: energy, consumables, and main- tenance and disposal. A reputable filter supplier should have soft- ware to help you perform the calculations. The TCO evaluation will ultimately save you money, time, and energy by ensuring the most cost-effective filter choice. (Note: A detailed article on TCO appeared in the August, 2010 is- sue of Powder Bulk Solids and can be accessed at www.powder- bulksolids.com.) 4. Consider a nano fiber me- dia even if you do not have a “difficult” dust challenge. When they were first introduced to the market, nano fiber media were regarded as a high-end choice lim- ited to exotic or demanding dust- capture challenges. Though these filters carry a cost premium, their use is becoming more widespread for all types of applications as processors come to understand their benefits. Compared to stan- dard media, nano fiber filters of- fer higher filtration efficiencies as well as better energy perfor- mance, superior cleanability, and greater resistance to wear and tear from pulse-cleaning. Because of these benefits, some filter ex- perts believe nano fiber media will become standard in the fu- ture. As a rule of thumb, if you are looking for high initial filtration efficiency and better release of dust through surface loading, then nano fiber media should be the default choice. Beyond this, even for a “non-high-perfor- mance” application, a TCO analy- sis (above) might be worthwhile to find out if the added cost of nano fiber media will be more than offset by resulting savings in energy and filter change-out and disposal costs. In a system operating at very high airflow, for example, a half-inch reduc- tion in pressure drop achieved with a nano fiber filter can make a huge difference in energy con- sumption. 5. Look for a uniform wide pleat media design. Many filter manufacturers add filter media to the point where the pleats are so tightly packed that when dust gets between the pleats, the re- verse pulse cleaning system of the dust collector will not eject the dust from the pleats. This in- creases the resistance of the air through the filters and diminishes airflow. The key is to use a wide pleat where 100 percent of the media is usable. A wide pleat filter allows the collected dust to release from the filter, keeping the resistance lower through the filter for a lon- ger time. Some wide pleat filters use state-of-the-art technology of synthetic bead pleat separators to ensure pleats are kept wide and open for the best dust release possible. These separators pre- vent the media from folding over on itself, which could cause the filter to plug. A wide pleat filter will often contain less total media area than a tightly pleated model. But the total square footage of the media is not what you want to look for: It’s the total usable media area that’s really impor- tant. Rick Kreczmer has held numer- ous positions with Camfil APC in the U.S. and Europe, and cur- rently serves as aftermarket sales manager. Camfil APC is a leading manufacturer of dust collection equipment and is part of Camfil, the largest air filter manufacturer in the world. Kreczmer can be reached at 800-479-6801, 870-933-8048, or filterman@camfil.com. Open-pleated media allows the collected dust to release from the filter, keeping the resistance lower through the filter and extending filter life. This exploded view shows internal pleat separation technique. Tightly pleated filter tends to trap dust within the pleats. Base media with nano fiber coating Base media with no coating buntingmagnetics.com(800) 835-2526 ©2014 Bunting® Magnetics Co. Complete Protection Protect your equipment and keep your product pure. quickTRON™ 05 Metal Detector Cost effective metal detector for the examination of bulk material in gravity free-fall applications. Pneumatic HF Series Drawer Magnet Designed for separation in enclosed flow lines and equipped with the most powerful magnetic cartridge to handle a wide range of separation tasks. ES466879_PB1408_016.pgs 07.18.2014 02:32 UBMblackyellowmagentacyan
  17. 17. www.PowderBulkSolids.com 17 August2014 TechnologyReview REMBE® INC., USA 3809 Beam Road, Suite K | Charlotte, NC 28217 T +1 (704) 716-7022 | info@rembe.us | www.rembe.us REMBE® GmbH Safety+Control Gallbergweg 21| 59929 Brilon, Germany T +49 2961 7405-0 | sales@rembe.com | www.rembe.com USAZ-QR3-6T-14800/0 Indoor Flameless Explosion Venting Approved for use with metal dusts SAFETY is for life. Q-Rohr®-3 www.cyclonaire.com 800.325.3138 Years WE HAVE THE APP FOR YOU. Dust Collection Air Pollution Control ProductFocus Spark Detection and Suppression The pneumatic conveying of com- bustible dusts carries inherent risks for dust fires and explosions in many applications. Grinding, cutting, and drying operations can often cause sparks that are typi- cally the ignition source for fires and explosions in duct collectors and air filtration equipment. The FLAMEX system is specifically de- signed to address these hazards by detecting and suppressing sparks in the pneumatic ductwork before they can reach dust collectors or storage bins. Infrared detectors sense sparks being transported through ductwork to a dust collec- tor. The system then triggers an extinguishing device located down- stream from the detectors and ef- fectively extinguishes the spark. FLAMEX Inc., Greensboro, NC 336-299-2933 www.sparkdetection.com Dust Collectors with Roto- Pulse Cartridge Cleaning Process dust and powders are controlled by the high-volume air cleaning offered by large-capacity dust collectors from Micro Air Clean Air Systems. The exclu- sive Roto-Pulse cartridge cleaning system automatically cleans the filter cartridges with up to 99.9% efficiency, facilitating lower main- tenance costs and longer filter life. The modular design allows mul- tiple units to be bolted together to handle even the largest air clean- ing requirements. Micro Air Clean Air Systems, Wichita, KS 866-566-4276 www.microaironline.com Progressing Cavity Pump The Moyno 2000 HS system can pump filter cake further distances with high volumetric efficiencies. Its twin-screw feeder supplies a constant, pressurized feed rate to the pump resulting in a 100 percent pump cavity fill rate. The sys- tem features an integral hopper with a twin-screw auger feeder and specially designed progressing cavity pump that efficiently handles dewatered municipal sludge to over 50 percent solids. The enhanced design of the Ultra-Feed pump rotor provides high volumetric efficiency. Moyno Inc., Springfield, OH 877-486-6966 www.moyno.com CONSTRUCTION – Sanitary; all metal magnesium alloy APPLICATION – Accurate sizing of dry, free-flowing materials and sanitary sizing of dry foods and food products. SEPARATION – Feed sizes – 200 mesh to 1/4 inch. SCREENING AREA - 10 to 35 square feet available with 2 to 7 decks for separating into 2, 3, or 4 products. SANITATION – Easy breakdown for cleaning; optional view ports available (800) 367-3591 sifterparts.com SIFTER PARTS SERVICE, INC. New Used CS-1 Sifters, Parts Repairs Why Choose A CS-1 Gyratory Sifter Large Screening Area Provides greater screening capacity in a smaller foot print Magnesium Alloy Screen Decks Allow thorough cleaning with air, brush or water Optional View Ports Inspect screens without disassembling of sifter Separate Bottom Hopper Permits quick replacement of stack without disconnecting discharge tubes Dynamically Balanced Drive Smooth, quiet, vibrationless operation Complete In One Package Self-contained screening and sizing unit with a maximum of 35 sq. ft of screen area. Approximate weight, 1000 pounds Food Safety Magnetic screens, Metal detectable polyballs cubes, FDA approved gaskets Low Operating Cost 1-hp motor is ample to operate units of 2 to 7 decks View of Screen Mesh Through Inspection Port PLENUM BAGS, CATCH CLOTHS, POLY BALLS, RECLAIM SIFTERS GUM RUBBER TUBING, CUSTOM DUST BAGS, OEM BAGHOUSE FILTERS ES466040_PB1408_017.pgs 07.16.2014 02:28 UBMblackyellowmagentacyan
  18. 18. Powder Bulk Solids18 Editor’sSpotlight August2014 • Pneumatic Conveying Low-Pressure Continuous Dense Phase Convey System for Fragile Material The E-finity is a patented continuous dense phase convey system for fragile materials. Precise pressure monitoring and airflow cor- rections allow the system to operate efficiently under all conditions, while gently inducing materials through the convey line in slug form. E-finity is ideally suited for granular and pel- leted materials, and has proven itself on many projects for pet foods, cereals, nuts, grains, and prills. E-finity air controls can employ a single air source to operate 2-3 different systems si- multaneously. The result is a cost savings in both equipment and installation, with contin- ued savings in operation and maintenance mov- ing forward. Schenck Process, Kansas City, MO 800-821-2476 www.macprocessinc.com Patented ECOPhase Pneumatic Conveying System The patented ECOPhase pneumatic conveying technology uses a specially designed entrainment device called a “Magveyor” to al- low a system to operate continuously while achieving high solids loadings and allowing the conveyor to run more efficiently. This can be of advantage to a manufacturing facility in either of two ways: it will allow a new installation to reduce the horsepower needed to convey dry bulk solids for a given rate and distance, or it will allow an existing installation to run more efficiently on existing horsepower, increasing the maximum throughput for a given line. Smoot Co., Kansas City, KS 800-748-7000 www.magnumsystems.com Batch Weigh Vacuum Convey System Vac-U-Max has supplied a batch weigh vacuum con- vey system that can be used in the food, pharmaceuti- cal, or chemical industries. This system is designed to deliver powders and granules to your process ves- sels with a high level of accuracy - with ½% of the batch size. This type of vacuum convey system allows for greater control of product quality and inventory control of materials. Material can be conveyed from drums, bags, or super sacks. Complete systems are available and the equipment is custom designed for the specific needs of the application. Vac-U-Max, Belleville, NJ 800-822-8629 www.vac-u-max.com Vacuum Conveyors Move Material without Plant Air Hapman’s line of vacuum conveyors convey powders, granules, flakes, and pellets up to 18,000 lb/hr. The convey- ors are engineered with a PD pump or regenerative blower to create vacuum without the need for plant air, increas- ing energy efficiency and lowering oper- ating costs. Its tool-less, side-door filter access provides installation flexibility – even allowing mounting near the ceil- ing, and making cleaning fast and easy run after run. These vacuum conveyors move products vertically, horizontally, around corners, on multiple levels, and long distances with minimal opera- tor attention or maintenance. They are ideal for conveying powders, dusts, granules, flakes, and pellets in continuous or batch processes. Hapman, Kalamazoo, MI 800-427-6260 www.hapman.com Mini-Fluidizer Promotes Material Flow Solimar Pneumatics has added a smaller version of its disk-type fluidizer. This 2-in.-diam Mini Disk fits in pipes, chambers, chutes, and small hoppers to enhance flow of powders and dry bulk mate- rial in pneumatic conveying systems. Because of its compact size, the Mini-Disk fits in curvatures as small as 4 in. In all applications, these fluidizers prevent bridging, rat holing, and material hang-ups. The aeration of the disk fluidizer utilizes directional air flow along the wall of the chamber or pipe to loosen product and move it to the discharge point. Gentle vibration is provided at the outer edges of the disk to keep powders and bulk solids flowing. Because the disk seals tightly against the chamber or pipe wall, there is minimum back pressure. This design advantage also prevents airline plugging. All Solimar aerators are compatible with food grade materials and are FDA approved. Solimar Pneumatics, Minneapolis, MN 800-233-7109 www.solimarpneumatics.com Pneumatic Conveying of Highly Caustic, Corrosive Material Specially treated to transfer a highly corrosive, granular material, this pneumatic conveying system uses integrated automation to mini- mize human exposure to the material and to optimize process efficiency with the upstream bulk bag unloading system. To reduce wear, the pneumatic conveying system is constructed of specially coated stainless steel tubing and com- ponents. Process-critical components and valves are Teflon coated. Pneumatically conveyed ma- terial is transferred to the downstream wetting process, in batches, based on calls from weigh system sensors. Total system capacity exceeds 9500 lb/hr. NBE integrated automation central- izes system control, communication, monitoring, and reporting using NEMA 12, dust-tight enclo- sures, and a single, UL-listed HMI. National Bulk Equipment Inc., Holland, MI 616-399-2220 www.nbe-inc.com ES466024_PB1408_018.pgs 07.16.2014 01:57 UBMblackyellowmagentacyan
  19. 19. www.PowderBulkSolids.com Editor’sSpotlight 19 August2014 • Pneumatic Conveying Conveying Process for Plastic Production Plants The pellcon3 conveying process pro- vides a solution for plastic processors who are upgrading existing plants or building new ones. This technology consists of the three process compo- nents: Strandphase conveying, Pellbow pipe bends, and the DeDuster for fines removal. Unlike dense phase systems, the pellcon3 process does not create dynamic forces throughout the line, reducing costs for building construc- tion and silos. Maximum conveying pressure is below 22 psi, making use of medium pressure rotary valves and blowers possible, and the flexibility of turndown ratios in a Strandphase system allows operation without an additional air management system. With pellcon3, conveying line sizes are smaller than in dilute phase or dense phase systems, and the efficient use of energy provides additional savings in the ongoing cost of operation. Pelletron Corp., Lancaster, PA 717-293-4008 www.pelletroncorp.com High-Pressure Blowers The conveying of material-laden air with fans involves determining the bulk density of the material to be conveyed. An appropri- ate amount of dilution air will be determined and a fan selected. High-velocity air is used to carry dirt, weld fumes, grain, plastic ma- terials, wood waste, and paper trim from a process to a collection point. BC pressure blowers are designed for high-pressure, indus- trial-process applications. All applications can be handled in either induced-draft or forced- draft configurations. Modifications and accessories make BC pressure blowers suitable for a wide range of systems, especially pneumatic conveying. The New York Blower Co., Willowbrook, IL 800-208-7918 www.nyb.com Food and Pharma Vacuum Conveyor A new conveyor line from Piab, piFLOWp meets the high demand from the food and pharma industries. The vacuum generated by piFLOWp is produced in an energy-efficient way, utilizing Coax cartridges. The Coax car- tridges are smaller, more efficient, and more reliable than conventional ejectors, which allows for the design of a flexible, modular, and efficient vacuum system. A vacuum sys- tem based on Coax technology can provide your customer with three times more vacuum flow than conventional systems, while reducing energy consumption. pi- FLOWp is designed according to USDA and GMP guidelines. All materials are FDA approved and all configurations can be delivered with an ATEX Dust certificate. Piab, Hingham, MA 800-321-7422 www.piab.com Heavy Duty Material Handling Hose Tigerflex Voltbuster is a lightweight, thermoplastic material handling hose that safely dissipates static charge in extremely high-static applications. The Voltbuster hose solves the problem of in- dustrial hose propagating brush discharge, otherwise known as “hose arcing,” which occurs when the static generated inside the hose overloads the dielectric strength of the hose tube. The conse- quences of electrostatic discharges range from personnel experiencing serious physiological shock to a potentially fatal dust cloud explosion. The hose can be used at any facility handling powders, plastics, or other granular materials, offering a lightweight alternative to cumbersome metal and industrial rubber hoses. The hose can be used without workers’ fear of getting “shocked,” while at the same time being lightweight and flexible enough to maneuver without worker strain. Kuriyama of America Inc., Schaumburg, IL 847-755-0360 www.kuriyama.com Oil-Free Rotary Screw Compressors For dense phase pneumatic conveying, Atlas Copco’s ZE/ZA range of oil-free rotary screw compressors offers a constant air flow at minimal energy costs. Delivered ready for use, ZE/ZA compressors come as all-in- one packages, including integrated variable speed drive (VSD), controller, and optional integrated after-cooler. VSD technology yields an approxi- mately 35% increase in energy savings by matching compressor flow to the required air demand, and the enclosed IP55 motor is built to ensure continuous operation and reliability even in dusty and humid environ- ments. ZE/ZA compressors are also 100% certified Class 0 according to ISO8573-1 standards, delivering 100% pure oil-free air for critical applica- tions such as pneumatic conveying, where compressed air comes into direct contact with the end product. Atlas Copco Compressors LLC, Rock Hill, SC 866-546-3588 www.atlascopco.com AIRLANCO has more than 35 years of experience building top-quality, custom dust collection and aeration systems. The RLP Low-Pressure Reverse Air Filters are engineered for efficient operation in demanding installations with high airflow and dust loads. The reverse air design utilizes an on-board direct-drive fan that minimizes energy consumption and maintenance costs by eliminating the need for compressed air or external blowers. AIRLANCO’s catalog of dust collection solutions also includes the E-86 filter, CHC (Compact Horizontal Cartridge) filter, as well as the AVS and AST Pulse Jet Filters. Contact AIRLANCO today for your custom CLEAN AIR solution. TOUGH. DEPENDABLE. CUSTOMIZED. 800.500.9777 | airlanco.com ES466872_PB1408_019.pgs 07.18.2014 02:29 UBMblackyellowmagentacyan
  20. 20. Powder Bulk Solids20 Editor’sSpotlight August2014 • Pneumatic Conveying Pneumatic Air-Vey Magnets Air-Vey magnets are designed to remove ferrous contaminants from products in dilute-phase pneumatic conveying systems that operate at 15 psi or less. These units are used to ensure product purity and protect process equip- ment. The flow-through area of the housing is engineered to maintain the same product velocity without an appre- ciable drop in pressure. These magnets install easily in horizontal, vertical, or angled positions with compression-type couplings or via welding in place. Puritan Magnetics Inc., Oxford, MI 248-628-3808 www.puritanmagnetics.com Pneumatic Weigh Filling System This pneumatic gain-in-weight filling system conveys and weighs free-flowing bulk solids, and discharges the material into bulk bags dust-free. The filter receiver of a Pneumati- Con vacuum dilute-phase pneumatic conveying system is mounted on load cells, enabling the controller to stop the flow of material once an accurate batch weight has been accumulated. A “fill” button on the Twin-Centerpost bulk bag filler actuates a blower to remove bag creases, and then opens a slide gate valve to discharge the batch into the bag at high rates, as a vibratory deck densifies the material to stabilize the bag. The filler is mounted on a secondary set of load cells to check-weigh the filled bag. A port within the discharge spout vents displaced air and dust to a remote bag house. The controller then releases the bag straps and deflates the spout seal, allowing the operator to tie-off the spout and remove the filled bag. Flexicon Corp., Bethlehem, PA 888-353-9426 www.flexicon.com Rotary Valves Coperion K-Tron offers Heavy Duty (HD), Maximum Duty (MD) and Quick-Clean (QC) Aerolock rotary valves, as well as Light Duty (LD) and Blow-Through (BT) models. Coperion K-Tron’s rotary valves are available with round or square inlet/outlet configurations providing 6- through 20-in. openings. Standard materials of construction include cast iron or stainless steel housings and end plates with carbon steel or stainless steel rotors. The housing and end plates can be coated with specified material for greater wear resistance. These rotary valves have met CE certification and ATEX 3D classifications. Coperion K-Tron Salina Inc., Salina, KS 785-825-3884 www.coperionktron.com Pocket Elbows The Dense Flow Pocket Elbow is designed for use on pneumatic conveying pipelines, and is most effective when highly abrasive materials are being transported. During a pneumatic convey cycle, the elbow traps incoming material at the elbow’s deflection point. The material that is trapped in the “pocket” then acts as a barrier for any remaining material being conveyed, and greatly increases the lifespan of the elbow. The Pocket Elbow can directly replace any existing pneumatic elbow when combined with Dense Flow Pipe Stubs. The advantages of the Dense Flow Pocket Elbow are increased elbow lifespan, less downtime, lower maintenance costs. JDB Dense Flow Inc., Palm Harbor, FL 800-822-3569 www.jdbdenseflow.com Flex Tube Diverters Eliminate Cross-Contamination Vortex Flex Tube Diverters eliminate material cross-contamination commonly found in the food, plastic, and chemical industries. They are ideal to divert, or converge, a wide range of dry mate- rials, including sugar-based solids, in gravity or dilute phase pneumatic conveying systems. Flex Tube Diverters feature two or three ports that utilize a basic sliding orifice blade design. A tube stub is welded to an orifice-style blade, and a flexible hose is then attached to the tube stub. As the diverter blade is shifted, a flexible hose moves from one port to the other, allowing the con- venience of continuous conveying. When one port is open, the other ports are sealed and elimi- nates any internal ledges or pockets where material can become lodged and remain trapped. Vortex Valves, Salina, KS 785-825-7177 www.vortexvalves.com Pneumatic Conveying Components Morris Coupling offers components for pneu- matic conveying systems, including: pipe and tube bends, straight pipe and tubing, quick- on and gripper couplings, welded fabrica- tions, flexible hose, installation components, extended wear bends, cam and groove cou- pling, and the original Morris compression coupling. Morris Coupling Co., Erie, PA 800-426-1579 www.morriscoupling.com Blowers for Pneumatic Conveying Tuthill Vacuum and Blower Systems manufactures blowers used in pneumatic conveying and blending within the food and beverage industry. PD Plus blowers are heavy-duty, high-pressure industrial blowers. PD Plus blowers are utilized in applications like pneumatic conveying where high-pressure, high-volume air is required. Seal areas are vented to atmosphere to relieve process against the internal lip seals and to provide oil-free air. Tuthill Vacuum Blower Systems, Springfield, MO 800-825-6937 www.tuthillvacuumblower.com ES466026_PB1408_020.pgs 07.16.2014 01:57 UBMblackyellowmagentacyan
  21. 21. www.PowderBulkSolids.com Editor’sSpotlight 21 August2014 • Pneumatic Conveying Dense Phase Pneumatic Conveying Systems Dynamic Air pneumatic conveying systems handle a wide range of materials and bulk densities at rates from 500 lb/hr to 450 tn/hr, over distances to 6000 ft. Each system is custom-designed from one of 16 different conveying concepts to provide a conveying solution that fits the process perfectly. One conveying concept, the Full-Line Concept system, has many advantages over more traditional dense-phase concepts with regard to degradation and energy consumption. In addition, it is clean and totally enclosed and can be fully automated to convey to packaging or process bins. Few moving parts are utilized, as the prime mover is standard plant compressed air at 100 PSIG. Cross contamination is never an issue as the convey- ing line can be purged clean when switching between materials. Dynamic Air Inc., St. Paul, MN 651-484-2900 www.dynamicair.com Blow-Through Feeder/Airlock Fine powders can easily over-aerate, which reduces material feed efficiency in high-pressure pneumatic conveying applications. ACS Valves designed the BT Series blow-through feeder/ airlock to ensure optimal throughput of hard-to-convey materials. The BT Series 12-vane rotary valve design decreases excess aeration of the material during conveying with an integrated vent port on the return side of the valve housing that vents pocket air leakage. The BT design element minimizes the flow path of air through the rotor clearances, improving ma- terial pocket release. With minimal air leakage, the resulting low, effective pressure drop of the BT Series optimizes ma- terial flow density, improves material conveying efficiency, and reduces total compressed air consumption. ACS Valves, Caledonia, ON, Canada 800-655-3447 www.acsvalves.com Pneumatic Conveying Accessories Lorenz diverter valves and gates are manufactured for gravity, vacuum, and dilute phase pressure convey- ing systems. Customized configurations are available to meet client requirements. Couplings are available in either quick release T-handle models for frequent access or bolted models for more permanent applications. Quick Release couplings are manufactured of 100% stainless steel. Bolted models are available in either gal- vanized or stainless steel. Lorenz tube and pipe bending service ensures quick delivery on long radius bends in aluminum, stainless steel, carbon steel, and galvanized. Fittings, reducers, tube and pipe straights, flex hose, and camlocks complete the line of products. Lorenz Conveying Products Corp., Cobourg, ON, Canada 800-263-7782 www.lorenz.ca Custom Pneumatic Conveying Systems PPS offers pressure and vacuum con- veying systems for virtually any ma- terial, capacity, or conveying length required. An on-site lab is available to test new products with unfamiliar properties. Custom options enable PPS to provide a dilute- or dense-phase system that will gently convey valu- able bulk powders with accuracy, reliability, efficiency, and minimal maintenance. Powder Process-Solutions, Chanhassen, MN 877-933-2556 www.powder-solutions.com Are your wooden pallet prices through the roof? Visit Litco.com for “Buy it Now”, Bulk Buy RFQ and a Free Sample •Meets IPPC-ISPM 15–“Pest Free” Requirements •Mold Free–Clean and dry •Small Sizes–24”x40” and Half Euro as low as $3.95 •Large Sizes–Domestic and Euro as low as $6.75 All Litco products are designed to Carry your products safely on through the most demanding supply chains TRY LITCO’S INTERNATIONAL SHIPPING PALLETS 48”×40” AS LOW AS $6.75EACH 855.296.2891 48 x 40 Buy Now No Nails To Puncture Bags Energy-Efficient Pneumatic Vacuum Conveyors The design of Volkmann pneu- matic conveyors ensures secure, reliable, and environmentally safe powder handling and transfer throughout the production process, as well as making the work of production staff simpler, offering a cost-effective material transfer method for powders and small par- ticles. In addition to offering dust- and emission-free operation, advan- tages of these pneumatic conveyors include: easy material aspiration and dust-free loading of machines; gentle conveying, no separation or segregation of material blends; optimum hygiene conditions; quick-change filter systems in cGMP quality; simple installation and operation; low energy consumption; all pneumatic operation with one simple air hook-up; energy-efficient Multijector vacuum pumps. The conveyor’s modular design allows custom- ized modifications to suit the individual requirements of applications within the food, chemical, pharmaceutical, or coatings industries. Volkmann Inc., Hainesport, NJ 609-265–0101 www.volkmannUSA.com Normal, IL 1IPOF t'BY Web: www.smsint.com t Email: smsint@aol.com t Slide Gate t Diverter t Rotary t Conveying Diverter t Scale t Custom Slide Gate t Iris — Manual Pneumatic Representing The pulse of your production depends Our valves will keep you moving. Powder control valves designed for a steady beat. One bad valve can ruin everything. ES466025_PB1408_021.pgs 07.16.2014 01:57 UBMblackyellowmagentacyan
  22. 22. Powder Bulk Solids22 August2014 TechnologyReview 800.880.DUST www.cwmfg.com DUST CONTROL SOLUTIONS Te Dust Control Experts since 1978. For Every Application • Explosion Proof • Stainless Steel • High Temp Units • Galvanized Units • Fire Suppression Systems • High Capacity/24 hrs day facilities • 99.99% filtration efficiency Food Processing Sand Terminal ProductFocus Dust Collection Air Pollution Control Mobile DeDuster for Large-Scale Bulk Loading Dust in bulk solid materials including plastic resins, minerals, metal ores, aluminum chips, tablets, granular foods, etc., may cause environmental hazards, housekeeping concerns, or reduced quality in the end product. As a result, the removal of dust and other contaminants is an important part of the material handling process. The DeDuster dust removal system removes dust and other contami- nants to a low level. The DeDuster is wear-resistant and can be used to clean all kinds of abrasive materials. The 3D image shows a DeDuster in a bulk loading area. Pelletron Corp., Lancaster, PA 717-293-4008 www.pelletroncom.com Dust Collectors with Round Filters Wamflo dust collectors can be used for both venting and suction applica- tions with a wide range of centrifugal fans in a variety of applications in virtually all industrial sectors. They are equipped with a cylindrical shape, 304 and 316 stainless steel body with flanged or clamped connection that contains vertically mounted filter elements. Specialized for different sectors and applications, the filter ele- ments can be chosen among pleated cartridges or Polypleat and flat round bags or elliptical bags. WAM USA Inc., Lawrenceville, GA 770-339-6767 www.waminc.com Dust Collector with Product Contact The product contact dust collector has a 304 stainless steel body for use in food, dairy, and pharmaceuti- cal industries. Top- and bottom-load designs are available. The model pic- tured features a bottom-load design that uses either high-efficiency filter bags or filter cartridges. Each collec- tor is designed and sized to suit spe- cific applications and requirements, offering custom solutions and orien- tations. PPS can help plants comply with OSHA and NFPA regulations. Powder Process-Solutions, Chanhassen, MN 877-933-2556 www.powder-solutions.com Dust Suppression Hopper The Dust Suppression Hopper (DSH) concentrates the discharge of dry goods as a solid column into any target repository including trucks, rail cars, ships, storage containers, or stockpiles. The system is sized based on an application’s load out rate and bulk density, and then sim- ply installed under a feed point. The DSH does not require any electricity or compressed air to operate. There are no internal moving parts and little maintenance is required once the unit is installed. A separate dust extraction system is not needed as a majority of the dust is maintained in the product stream. The DSH system has been proven successful in fertil- izer, grain, mineral, and foodstuff ap- plications around the world. Systems can be manufactured from a range of materials. Sioux Steel, Sioux Falls, SD 800-557-4689 www.dustsuppressionhopper.com High-Capacity Fans Capture and control of emissions is accomplished by creating air move- ment. Every type of fan design can be used to move air through a filter or process scrubber. The fans can be installed on the clean side of the cap- ture device that calls for NYB junior, general purpose, or AcF/PLR/BC designs. Dirty air fans for capture de- vices would require general industrial or RTS designs. These capture de- vices can be designed for continuous operation or shut down regularly for cleaning. Occasionally the air is cor- rosive or contains abrasive particles and requires special construction to resist wear. The New York Blower Co., Willowbrook, IL 800-208-7918 www.nyb.com PIVOTAL EDGE DRY BULK PNEUMATIC TRAILER COVER PIVOTAL EDGE P.O. Box 2636 Bismarck, ND 58502-2636 P: 701.223.0543 www.thepivotaledge.com jay@thepivotaledge.com ES467114_PB1408_022.pgs 07.18.2014 20:19 UBMblackyellowmagentacyan
  23. 23. www.PowderBulkSolids.com 23 August2014 TechnologyReview Patented design delivers superior performance Searching for the best equipment? Take a closer look at the features of our Material Master™ Discharger: O Patented technology O ([FOXVLYHGXVWWLJKWDQGÀRZHQKDQFHPHQWRSWLRQV O /RVVLQZHLJKWRUJDLQLQZHLJKWVVWHPV O 0RGXODUGHVLJQFXVWRPL]HGIRURXUDSSOLFDWLRQ O 6WDLQOHVVVWHHORUFDUERQFRQVWUXFWLRQWRRXUVSHFL¿FDWLRQ O 8QPDWFKHGTXDOLWVHUYLFHLQWHJULWDQGYDOXH MATERIAL MASTER ™ BULK BAG DISCHARGER Dust Collection Air Pollution Control ProductFocus SplitStream Counter Cyclonic Dust Collector The SplitStream is a counter-cyclonic dust collec- tor that has no major moving components and is capable of handling a wide range of materials, all while requiring minimal maintenance. Its design ensures that a minimal amount of particulate comes in contact with the interior walls of the col- lector. This eliminates excess wear and enables the collection of abrasive particulate. Unlike other cyclonic dust collectors, the SplitStream can be configured in both vertical and horizontal designs. With a wide range of sizes and installation options, it is ideal for nearly any plant space layout. The versatility of this counter-cyclonic dust collector means lower installation costs and lower mainte- nance. It is ideal for wet, sticky, or hydroscopic applications and fibrous dust that would typically bind or cause issues with fabric filters. Aerodyne Environmental, Chagrin Falls, OH 800-358-7546 www.dustcollectorhq.com Capturing Bulk Transported Lime Dust Weekly tanker truck deliveries of hydrated lime are pneumatically conveyed to an outdoor storage bin (silo). A dust collector is required to allow the conveying air to exhaust, without pressurizing the silo and preventing any of the conveyed lime from escaping and discharging to the environment. Sternvent manufacturers a bin vent-style dust collector with a flanged open bottom for mounting on the roof of the silo. It is available in jet-pulse filter bag and car- tridge styles, as well as filter bag with automatic shaker. Options include: a top-mounted, direct- drive 5-hp blower; internal safety grating; motor controller; mounting transition to allow easy retrofit of a new bin vent dust collector to an existing silo and RAL color match to silo. Sternvent, Union, NJ 800-383-3878 www.sternvent.com www. .com Check out our Dust Collection Air Pollution Control Equipment Zone for the latest articles, equipment, and news PowderBulkSolids.com Check out our Equipment Zones for news and articles at PowderBulkSolids.com Division of Control Concepts,Inc. www.AirsweepSystems.com ES466326_PB1408_023.pgs 07.16.2014 21:18 UBMblackyellowmagentacyan
  24. 24. 24 August2014 TechnicalExclusive Figure 1 - Dust Explosion Pentagon I Secure Cloud-Based Industrial Monitoring Solution It is well known that transporting certain dry dusty materials can create explosive atmospheres. Five conditions, known as the “Dust Explosion Pentagon”, have to exist in order for the explosive state to oc- cur. First, there needs to be a high concentration of dust (fuel), followed by an ignition source (heat) and oxygen (oxidizer). If all of these appear in a confined space with dispersion, an explosion can occur. The most common ignition sources have long been iden- tified as over-heated bearings, misaligned belts, and belts that are slipping. The industry is saturated with various sensors and controllers that monitor these conditions to prevent explosions. Regardless how well these systems work there is one problem with all of them: human error. With the ever-growing demands on site performance and efficiency at ter- minals and processing facilities, decisions to bypass safety equipment has become an ever increasing is- sue. With mount- ing pressures, site personnel may risk keeping a machine in opera- tion even after an alarm has been detected, putting the plant and all personnel at risk. Without backend reporting systems and data logging, this dangerous practice can go on undetected by up- per management. In order to combat this issue, 4B Components has developed a solution that in- troduces a greater level of transparency and record keeping. HazardMon.com is a secure cloud-based industrial monitoring solution that allows any regis- tered user to log in and see all their facilities in real- time from anywhere in the world. This product of- fers seamless integration with 4B’s T500 Elite Hotbus hazard monitoring system. HazardMon.com Features Features of the HazardMon.com include the follow- ing: • Secure login and data transfer with standard 256- bit (SSL) encryption, or an optional virtual private network (VPN) connection can also be created • No server or PLC is required, so there is no ad- ditional hardware to replace or backup, which also eliminates upkeep and upgrade costs. • Data is sent directly to 4B’s cloud server, and automatically backed up in multiple off-site locations making the data extremely safe and secure. This al- lows data to be easily recovered and analyzed in the case of an on-site event, such as an explosion. • Live system dashboard, historical data, and cus- tomizable graphs can be viewed on any Web-enabled device (smartphone, tablet PC, desktop or laptop computer). • Email alert notifications can be sent to notify specific users whenever a change in the system’s health is detected. • New features are constantly being developed to improve the end user experience, and with HazardMon.com’s cloud-based technology, your facil- ity will always be at the leading edge of technology. Live System Dashboard With HazardMon.com it is possible to view multiple sites from one system dashboard page (see figure 3). This unique feature varies from other systems where you have to log in to each site individually and view them one by one. HazardMon.com also indicates all active alarms from all facilities in one place as soon Figure 2 - HazardMon.com Running on Different Devices Figure 3 - HazardMon.com System Dashboard ES467842_PB1408_024.pgs 07.22.2014 00:17 UBMblackyellowmagentacyan
  25. 25. www.PowderBulkSolids.com 25 August2014 as you log in, allowing managers to see any problems in a matter of seconds. All sensor data can be viewed in real-time using any standard Web browser such as Mozilla Firefox, Google Chrome, or Internet Explorer (see figure 4). The Web site is completely dy- namic and the sensor status and value are updated automatically without the need to refresh the webpage. The Web site was de- signed to dynamically resize as the screen resolution changes and it is optimized for tablet and mo- bile phone platforms. Historical Data Analysis All data can be viewed as graphs. A unique drag-and-drop feature allows you to pick specific sen- sors of interest and compare them side-by-side in one graphical view (see figure 5). Time windows can be selected, ranging from 1 hour to 30 days. The graphs are inter- active, allowing you to use your cursor to mouse over any event to show specific values and sen- sor statuses. All alarms are stored in a sepa- rate alarm log (see figures 6 and 7). Using the Web site filtering options, it is easy to generate a report and download it into a standard spreadsheet program. All the alarms are grouped into different alarm types, like “Alarm Detected”, “Alarm Cleared”, “Device Power Up”, etc. This al- lows information to be extracted in a few clicks and create a report in seconds. Email and Text (SMS) Notifications Engine A flexible notification system al- lows any user to receive email or text message notifications. Notification can be sent when sensors go in and out of alarm; when the Internet connection between the T500 Hotbus system and the server is lost or when an alarm has not been cleared for a number of minutes. It is also possible to receive notifications only when an alarm has not been cleared for a specified number of minutes. Report Generation Tool An advanced analytics tool allows reports to be generated that sum- marize the safety and efficiency of the factory. Currently it is pos- sible to see which sensors caused the majority of alarms, which hours of the day had most alarms, and the types of alarms. (See fig- ures 8 and 9) The start and end Figure 4 - HazardMon.com Live System View Figures 6 and 7 - HazardMon.com Alarm Log Filtered (above) and HazardMon.com Alarm Log Unfiltered (below) Figure 8 - HazardMon.com Types of Alarms Report Figure 5 - HazardMon.com Graphing: Two Bearings Shown, One is in Alarm 17 July 2013, 15:01:16 1.3 BEARING TEMP 7 :120 0 F OK 1.4 BEARING TEMP 1 :188 0 F Alarm Live 1 Hours 24 Hours 7 Days 30 Days ContactTemperature(F) 200 150 100 50 Sensors Temperature Alarms ok 40:00 50:00 00:00 10:00 20:00 30:00 40:00 14:45 15:00 15:15 15:30 –– 1.3 EARING TEMP 7 –– 1.4 BEARING 1 Types of Alarms Pie Chart Showing The Different Alarms Types. From: 01 Jul 2013 To: 17 Jul 2013 Belt Mis alignment Alarm: 28.56% Underspeed Stop: 14.28% NTC Temperatre Alarm: 42.89% Underspeed Alarm: 14.28% ES467499_PB1408_025.pgs 07.21.2014 20:50 UBMblackyellowmagentacyan
  26. 26. Powder Bulk Solids26 TechnicalExclusive August2014 dates of reports can easily be al- tered and the report re-generated. Reports can be saved to the user’s PC in a single click. Automated Maintenance and Testing Functionality It is important to periodically check that your monitoring sys- tem will detect an alarm when a dangerous condition occurs. The current standard in the industry is for technicians to walk around the site and manually test each sensor. A paper report is then generated and in some cases, converted into a digital format (Microsoft Excel for example). There is still absolutely no guar- antee that the technician actually performed any of the testing. HazardMon’s sensor testing func- tion ensures that test procedures are carried out, logged, and re- ported within the system. This feature provides managers docu- mented evidence that each sen- sor has been tested to ensure it is working correctly. (See Figure 10). To initiate a system test, a user would go to the “Maintenance” tab within HazardMon.com and choose a sensor to test. During testing, HazardMon temporarily stops alarm notifications for this sensor, so that no nuisance alarm notifications are sent out. The user has five minutes to trigger an alarm and confirm the sensor is in proper working condition or needs to be replaced. The whole process is logged automatically, and a maintenance report can be generated after testing has been completed. Conclusion As more facilities install moni- toring systems to ensure the site’s safety, the main safety concerns, human error, and the lack of transparency still exist. HazardMon.com combined with 4B’s hazard monitoring systems gives management real-time ac- cess to all critical monitoring data. This increases transparency, cuts down on human error, and helps to verify that company safety poli- cies are being adhered to. To see all of the features avail- able, sign up for a free demo ac- count at www.hazardmon.com. For complete product information Call Toll Free 1-800-263-7782 or VISIT OUR WEBSITE TODAY! Manufacturing Diverter Valves and Gates Gravity Diverter Roller Gate Slidegate Discharge Valve 2 Way Diverter Slideflex Diverter Maintenance Gate www.lorenzproducts.com Sensor Alarms Summary Bar chart showing Most Alarmed Sensors. From: 01 Jul 2013 To Jul 2013 NumberofDetectedAlarms 4.1 6.1 3.1 2.4 6 4 2 0 Figure 9 - HazardMon.com Number of Detected Alarms Figure 10 - HazardMon.com Maintenance Feature www. .com Check out our Explosion Protection Safety Equipment Zone for the latest articles, equipment, and news PowderBulkSolids.com Progressive Design, Progressive Manufacturing, Progressive Valves 1-888-235-1732 ROGRESSIVEValves • Heavy Duty, American Cast Iron • Maintenance Free Seals • Premium L10 Life Bearings Made in America • Relieved Rotor Edges and Sides • Seal Purge Tapped Endplates • Tight Precision Tolerances www.progressiveproductsinc.com Quality is the Difference ES467500_PB1408_026.pgs 07.21.2014 20:50 UBMblackyellowmagentacyan