Powder & Bulk Solids Magazine

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The Source for Dry Processing and Bulk Handl ing Technology

Official Publication of

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Vol. 32, No. 9• IN THIS ISSUEAUGUST 2014

Dust Collection System InvestmentPerforming 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 ConveyingThe 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

ApplicationsPage 14

ES467113_PB1408_001.pgs 07.18.2014 20:19 UBM blackyellowmagentacyan

http://www.ubmcanon.com/

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 degradationMove your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.

Proven capabilityDynamic 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 conceptsEach 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 effectiveOur high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation

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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.

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ES465186_PB1408_002_FP.pgs 07.15.2014 00:47 UBM blackyellowmagentacyan

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 DumpStations

Bullk BagFillers

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Storage Bins& Hoppers

Drum & ContainerDischargers

Bulk Bag Dischargers

Agitator Hoppers

Bag DumpStations

Bullk BagFillers

Bulk MaterialMixers

Storage Bins& Hoppers

Drum & ContainerDischargers

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 2Groups A-D, F, and G

System-wide process control,communication, sensing, andmonitoring are automated toensure 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, interlockingsafety 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


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 PlenumA 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 ValveDesigned 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 PlateA 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.


Flameless VentDesigned 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 SuppressionDesigned 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 VentDesigned 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 SuppressThese 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 COMPLIANTCOMBUSTIBLE DUST COLLECTION SYSTEMS

Isolation Flap Valve

TM

IT LOOKS LIKE A SAFE BECAUSE IT’S

www.camfilapc.com888-964-9342


Powder & Bulk Solids 6 Editor’sChoice

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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 fl uid 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 solidifi ed, 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 profi les that safely and effi ciently return

solidifi ed materials to a free-fl owing 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 overfi ll 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 refi ll

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 fi ll-

ing system palletizes and fi lls bulk bags

with fi lter cake, aggregates, metal powders,

abrasive minerals, dry chemical additives,

and other diffi cult-to-handle bulk materials.

The system integrates a Swing-Down bulk

bag fi ller with a Flexicon pallet dispenser

and powered chain conveyor, allowing

safe, high-capacity fi lling of bulk bags of all

popular sizes, including bags with wide-

diameter spouts for passage of irregular

materials. When a fi lling 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 fi lling station. The bag connection frame of the Swing-Down fi ll head lowers and

then pivots to a vertical position, allowing an operator at fl oor level to safely and quickly

attach bag straps to automated latches, slide the bag spout over a wide-diameter infl atable

spout seal, and press a spout seal infl ation button.

Flexicon Corp., Bethlehem, PA 888-353-9426 www.fl exicon.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


http://www.flexicon.com/


http://www.spiroflowknows.com

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IndustryInsight

P

Understanding the Long-Term Value of Dust Collection System InvestmentsTravis Haynam

[email protected]

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

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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 REMOVALLow profile version of patentedTWIN-CENTERPOST™ fillerallows removal of filled bags usinga pallet jack, eliminating the needfor a forklift or roller conveyor. Low cost standard models offered

with many performance options.

BULK BAG FILLER USESPLANT SCALEFull length forklifting tubes allow positioning of this TWIN-CENTERPOST™ filler model on aplant scale as needed, allowingyou to fill by weight withoutinvesting in load cells andautomated controls.

FILLERS WITH AUTOMATEDFEEDING SYSTEMSEvery Flexicon filler is offered withpneumatic (shown) or mechanical(bottom right) feeding/weighingsystems, as well as inlet adapters

to interface withoptional overheadstorage vessels.

COMBINATION BULK BAG/DRUM FILLERPatented SWING-DOWN® fillerfeatures a fill head that lowers and pivots down for safe, easy bagspout connections at floor level,and a swing-arm-mounted chutefor automated filling and indexing of drums.

PATENTED SWING-DOWN® FILLERFill head lowers, pivots and stopsin a vertically-oriented position,allowing operator to safely andquickly connect empty bags atfloor level and resume automatedfilling and spout-cinchingoperations.

CANTILEVERED REAR-POST FILLEROffered with performance optionsincluding: powered fill head height adjustment, pneumaticallyretractable bag hooks, inflatablebag spout seal, dust containmentvent, roller conveyor, and vibratorybag densification/deaeration system.

BASIC FILLER FOR TIGHTEST BUDGETSA lighter-duty version of theeconomical TWIN-CENTERPOST™filler, the BASIC FILLER reducescost further still, yet has aninflatable bag spout seal and feedchute dust vent as standard, and alimited list of performance options.

PATENTED TWIN-CENTERPOST™ FILLERTwo heavy-gauge, on-center posts boost strength and access to bag hooks while reducing cost.Standard manual fill head heightadjustment, and feed chute ventfor displaced dust. Numerousperformance options. First filler to receive USDA acceptance.

CC

-0710

Fill one bulk bag per week or 20 per hourat 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

[email protected] 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-freeFLEXICON® 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-freeTIP-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 pneumaticallyFLEXICON® 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 automaticallyFLEXICON® 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 conveyorFLEXICON® 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 bagsBLOCK-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.



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www.PowderBulkSolids.com

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Explosion

Venting/

Suppression

Q & AAnswered 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


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

[email protected] www.nol-tec.com

Call 651-780-8600 today to speak with

an experienced systems application engineer.


www.PowderBulkSolids.com 11

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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

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http://clarcorindustrialair.com/

Powder & Bulk Solids 12

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TechnologyReview


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 MicronHapman’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.com1-800-557-4689

Solves Dust

Fallout While Transferring

Dry, Granular Goods.

BEFORE

AFTER

DUST SUPPRESSION

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Kuriyama of America, Inc.

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http://www.magnetics.com/



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TechnologyReview


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 FiltersThere 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


http://www.vac-u-max.com/

http://www.vac-u-max.com/


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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 MediaThere 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 TipsFollowing 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.



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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 bendsJason 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.

PPneumaPneuma

radius prad us p

designe design

special spe

By design, material fl owing through the Pellbow® forms a pocket or

“impact zone” and moves slowly upward and out. Incoming material

is defl ected 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 fl ow 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 retrofi tted

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 fi t 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.


Powder & Bulk Solids16 TechnicalExclusive

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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

[email protected].

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 ProtectionProtect 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 MagnetDesigned for separation in enclosed flow lines

and equipped with the most powerful magnetic

cartridge to handle a wide range of separation

tasks.



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TechnologyReview

REMBE® INC., USA3809 Beam Road, Suite K | Charlotte, NC 28217

T +1 (704) 716-7022 | [email protected] | www.rembe.us

REMBE® GmbH Safety+ControlGallbergweg 21| 59929 Brilon, Germany

T +49 2961 7405-0 | [email protected] | www.rembe.com

USA

Z-Q

R3

-6T-

14

80

0/0

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.


ProductFocus

Spark Detection and

SuppressionThe 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


Powder & Bulk Solids 18 Editor’sSpotlight

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• 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


www.PowderBulkSolids.com Editor’sSpotlight 19

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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



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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



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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

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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

1IPOFt'BY

Web: www.smsint.com t Email: [email protected]

t Slide Gatet Divertert Rotaryt Conveying Divertert Scalet Custom Slide Gate

t Iris — Manual & Pneumatic

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The pulse of your production depends

Our valves will keep you moving. Powder control valves designed for a steady beat.

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Powder & Bulk Solids 22

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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


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 FiltersWamflo 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 ContactThe 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 HopperThe 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 EDGEP.O. Box 2636

Bismarck, ND 58502-2636

P: 701.223.0543

[email protected]


http://www.pelletron.com/


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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 /RVVLQZHLJKWRUJDLQLQZHLJKWV\VWHPV

O 0RGXODUGHVLJQFXVWRPL]HGIRU\RXUDSSOLFDWLRQ

O 6WDLQOHVVVWHHORUFDUERQFRQVWUXFWLRQWR\RXUVSHFL¿FDWLRQ

O 8QPDWFKHGTXDOLW\VHUYLFHLQWHJULW\DQGYDOXH

MATERIAL MASTER ™

BULK BAG DISCHARGER


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


Check out our

Equipment Zones

for news and articles


Division of Control Concepts, Inc.

www.AirsweepSystems.com


http://www.powderbulksolids.com/equipment-zones


http://www.materialtransfer.com/

24

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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 FeaturesFeatures 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 DashboardWith 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



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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 AnalysisAll 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 EngineA 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 ToolAn 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 0F OK

1.4 BEARING TEMP 1 :188 0F Alarm

Live 1 Hours 24 Hours 7 Days 30 Days

Co

nta

ct

Tem

pera

ture

(F

) 200

150

100

50

SensorsTemperature

Alarmsok

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%


Powder & Bulk Solids26 TechnicalExclusive

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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 FunctionalityIt 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.

ConclusionAs 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

Nu

mb

er

of

Dete

cte

d A

larm

s

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


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TechnologyReview

Coperion K-Tron New

Sanitary Filter Receiver

The Coperion K-Tron Sanitary

Filter Receiver (SFR) provides

automatic separation of product

material from the convey air for

vacuum and pressure conveying

sanitary applications in batch and

continuous processes. The SFR

is specifically designed for strin-

gent food applications requiring

quick clean-out and to reduce food

contaminants and/or the cross

contamination of allergens. The

unit is easily cleanable with round

corners, no ledges, and no hidden

areas. The tool-less side-entry ac-

cess door allows for safe and easy

cleaning of the unit.

Coperion K-Tron Salina Inc.,

Salina, KS 785-825-3884

www.coperionktron.com

High-Capacity Dust Collectors

C&W Manufacturing specializes in

dust control systems ranging from

100 to 50,000+ cfm for many in-

dustries. Pictured is a food-grade,

stainless steel CP-305 cartridge

pulse dust collector. These collec-

tors are designed for high-capacity

use and provide 99.99% filtration

efficiency. Explosion-proof, fire-

suppression, high-temperature

grounded units reduce static elec-

tricity.

C&W Manufacturing and Sales,

Alvarado, TX 800-880-3878

www.cwmfg.com

Adjustable Bracket

for Dust Suppression Ring Dust Control Technology has

introduced a family of adjust-

able mounting brackets for the

DustBoss DB-RTM series of dust

suppressors. The new bracket de-

sign is available to suit the entire

range of ring sizes from 17-100

in., and can be installed in about

an hour. The DB-R is engineered

specifically for use at conveyor dis-

charge points, designed to create a

virtual “curtain” of mist around the

material flow for outstanding par-

ticle containment. First developed

for a coal application, the DB-R

fully encircles the discharging ma-

terial to apply suppression directly

as the flow exits the conveyor. The

simple yet effective engineering

delivers focused dust suppression

on a continuous-duty basis, able

to capture fugitive particles on ra-

dial stackers and other offloading

points with a durable, intrinsically

safe design.

Dust Control Technology,

Peoria, IL 800-707-2204

www.dustboss.com

Bag Leak Detection

and Solids Flow Monitoring

Auburn’s TRIBO.dsp U3000 se-

ries of electrostatic/triboelectric

(TRIBO) bag leak detectors, emis-

sion monitors and solids flow

monitors effectively measure dust

emissions and dry solids flow

from a wide variety of industrial

processes including chemicals,

food, pharmaceuticals, metals, ce-

ment operations, and power/util-

ity industries. The conveying or

transporting of dry particulate for

manufacturing processes creates

the need to know if there is flow

in a pipe or feeder system.

Auburn Systems, Danvers, MA

978-777-2460 www.auburnsys.com


ProductFocus

Safety Solutions

for Conveyor Applications

Designed to prevent workers from

being drawn into a moving return

roller, the Martin Return Roller

Guard is an economical way to

raise safety awareness and reduce

injuries. The solid upper section

delivers pinch point protection, and

the slotted lower area allows visual

inspection while preventing contact

with the roller. Installation is straight-

forward, with brackets included to

mount the guard directly to either the

side or bottom of the stringer. The

Martin Return Roller Basket is de-

signed to prevent a return roller from

falling in the event of a mechanical

failure, recommended for rollers that

are more than 7 ft off the ground and

out of reach for any workers. Martin

Conveyor Guards simplify conveyor

guarding to improve plant safety and

productivity. The heavy mesh guards

allow easy inspection, while keeping

moving components and pinch points

isolated from workers. The rugged

modular design is supported by a sup-

plied angle iron structure, and attach-

ment to the conveyor equipment is

not required. Installation is straight-

forward.

Martin Engineering, Neponset, IL

800-544-2947 www.martin-eng.com

Auger Fillers

Telesonic Packaging Corp. offers a

range of auger fillers from its Model

DXD-180 with dual auger fillers to

the Model DCS-2B-2 auger can filling

machine. The stainless steel modular

design allows for easy disassembly

and cleaning to meet the stringent

hygiene standards of the food indus-

try (FDA). The design also provides

the ability to deliver large quantities

of powder and granular products at

high speed. Distinguishing features

of these auger fillers include: fill by

weight with automatic container feed-

ing with a weight checker scale; PLC

controls; color touch screen; servo

motor; easy viewing to see if more

product is needed and adjustable star

wheel; and conveyor with self-diag-

nostics display.

Telesonic Packaging Corp.,

Wilmington, DE 302-658-6946

www.telesoniconline.com


http://cedpackaging.com/



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• Instrumentation & Process Control

Explosion-Proof Bucket Elevator Alignment Control

The explosion-proof Model VA-X bucket elevator alignment control is designed to indicate when

the head or boot section of a bucket elevator drifts too far out of alignment. It can be used to signal

a problem or simply shut down the bucket elevator leg. The Model VA-X control device has a se-

quential two-pole double-break microswitch rated for 20 amps at 120, 240, or 480 VAC. The switch

actuation is field adjustable with a simple 3/32 hex wrench adjustment. The metal roller is sturdy

and bi-directional, and designed to survive in harsh environments. The housing is a rugged polyester

powder coated steel frame with a specially designed non-accumulating pocket. The microswitch is

rated NEMA Type 7/9 for use in hazardous locations. General purpose models are available.

Conveyor Components Co., Croswell, M810-679-4211

www.conveyorcomponents.com

Gladiator Microwave Products

The New Generation Gladiator Microwave is 50 times more sensitive and uses cir-

cular polarization rather than linear polarization. Not only does circular polariza-

tion allow for minimal signal loss,

the unwanted reflected signal does

not cancel out the signal on the re-

ceiver which is cause for concern in

linear polarized units. This increase

in sensitivity also allows for better

penetration through product and

product buildup.

Hawk Measurement,

Lawrence, MA 888-429-5538

www.hawkmeasure.com

Free Powder Sample Testing

Brookfield Engineering Laboratories offers free pow-

der sample testing using its PFT Powder Flow Tester

to characterize a powder’s behavior and flowability.

The testing determines flow function, wall friction,

arching diameter, and bulk density as a function of

consolidation stresses. Shear cell methodology is the

technical approach used to test all customer samples

in accordance with ASTM D6128, D6682, and D6773.

Rathole diameter and internal friction angle can also

be provided at the customer’s request. The testing is

typically completed in less than a week and the results

are emailed to the customer. These reports provide

customers with actual data that can be used to im-

prove their process by characterizing powders with

flow aids, and serve as a reference for future powder

formulations.

Brookfield Engineering Laboratories,

Middleboro, MA 508-946-6200

www.brookfieldengineering.com

Air and Electric Control Systems

The Dense Flow air and electric control systems are designed to achieve maximum conveying

results with minimal energy waste. An advanced air monitoring system closely monitors air

pressure during a convey cycle, and air is added only when necessary to achieve optimal con-

veying efficiency. The operator-friendly touch screen displays give operators the ability to moni-

tor critical data during a convey cycle, as well as make “on the fly” changes to certain param-

eters of the conveying system. Displays and controls are custom designed to individual needs.

JDB Dense Flow Inc., Palm Harbor, FL 800-822-3569 www.jdbdenseflow.com

In-Line Moisture

Measurement

System

Monitor Technologies

announces a moisture

measurement sensor

that uses high-fre-

quency field technology

to measure the moisture inside the material core - not just the surface. It is

a continuous in-line system that provides real-time data to ensure product

quality through moisture control. It allows for automation of drying or mois-

turizing processes to maximize profit. The sensor, which is easy to install

and calibrate, works with a large variety of powders and bulk solid materials.

Monitor Technologies LLC, Elburn, IL 800-601-6165

www.monitortech.com

Humidity and Temperature

Wireless Data Loggers

These humidity and temperature wireless

data loggers are suitable for the most di-

verse monitoring tasks. RF transmissions

save the user wiring cost, and data can be

recorded quickly and easily wherever access

is restricted. The data is sent as powered

NFC tags at 433 or 915 MHz and can be

received via a USB or LAN wireless adapter

up to 100 m away, depending on the envi-

ronment. The loggers are programmed and

data downloaded via Rotronic’s HW4 soft-

ware. HW4 and the LOG-HC2-RC are fully

compliant to FDA 21 CFR Part 11 require-

ments. Both single devices and groups can

be enabled for data readout.

Rotronic, Hauppauge, NY 631-427-3898

www.rotronic-usa.com



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• Instrumentation & Process Control

Powder Rheometer

The FT4 Powder Rheometer is a

universal powder tester that uses

patented dynamic methodology, a

fully automated shear cell, and sev-

eral bulk property tests to quantify

powder properties in terms of flow

and processability. These rheometers

are installed around the world in a

diverse range of industries includ-

ing chemical, pharmaceutical, ton-

ers, foods, powder coatings, metals,

ceramics, cosmetics, and many oth-

ers. They deliver data that maximize

process and product understanding,

accelerating R&D and formulation

towards successful commercialization,

and supporting the long-term optimi-

zation of powder processes.

Freeman Technology, Tewkesbury, UK

+44 (0) 1684 851 551 www.freemantech.co.uk

Compact Vibrating Rod for Small Bins

BinMaster introduces the new CVR-625 mini vibrating rod, a

compact point level control designed for use in small bins and

hoppers where other level sensors will not fit. The new ver-

sion features an updated design that allows for the detection of

light materials with a bulk density as low as two. The rod can

be used for measuring plastics, food, seed, chemicals, and other

pellets or dry granular solid materials. The signal from the elec-

tronic circuit of the CVR-624 excites the single rod of the instru-

ment to vibrate on its resonance frequency of approximately

460 Hz. When material covers the rod of the probe, the vibra-

tion stops. This is sensed by the electronic circuitry that forces

its output relay to switch. When the blade becomes uncovered,

the vibration will restart and the relay will switch back. Due to

its vibrating technology, the mini vibrating rod is able to over-

come the difficulties associated with changes in dielectric con-

stant, humidity, temperature, and material density, and elimi-

nates the problem of false signaling due to material wedging and

buildup associated with Ôtuning forkÕ type probes.

BinMaster, Lincoln, NE 800-278-4241 www.binmaster.com

Tel: 1-800-601-5949 or 1-630-365-9403 www.monitortech.com www.flexar.infoE-mail: [email protected] Blog: monitortech.typepad.com

Doing Our Doing Our LevelLeve l BestBest

FlexarFlexar®

Guided wave radar real-timelevel

SiloPatrol®

“Smart” plumb bob

To Measure & P ro tec tWho wants to climb silos? It costs time and presents safety issues.

Monitor Technologies’ level sensors provide a wide variety of solutions including:

TrueCap® MK-2

RF Capacitance withpush-button calibration

SiloTrackTM

Inventory managementsoftware

SafePoint®

Fail-saferotary paddle

Continuous level measurement and inventory management High, low and/or intermediate point level indication of stored materials Provide silo overfill protection Turn “on” or “off” other processes based on the detected

presence or non-presence of materialwww.

.com

Check out our

Equipment Zones

for news and articles


Vibrating Point Level Sensor

with Self-Diagnostics

The SC35 series vibrating fork point level

sensor uses state-of-the-art piezoelectric

crystal and electronic technology, does not

require any calibration, and can diagnose

potential problems, including material

buildup and abrasion to the primary sensing

elements. The vibrating fork point level sen-

sor can be used to detect the presence and

absence of bulk solid material over a wide

range of material densities. The minimum

density that the SC35 series can detect is

0.624 lb/cu ft. Other features of the level

sensor include self-diagnostics, a small com-

pact housing, universal 19-253VAC/VDC

power supply, and the availability of stan-

dard, pipe extended, high-temperature, and

cable-extended probe versions.

Aplus Finetek Sensor Inc., Sterling, IL

815-632-3132 www.aplusfine.com




http://www.rotodisc.com/

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TechnicalExclusive

caption

O

High-Tech Plastics Are Economical and

Environmentally FriendlyOne of the greatest advantages of plastic is that it

can replace heavier metal – resulting in more light-weight automobiles. DuBay Polymer GmbH is one of the world’s largest plants for the production of high-tech plastic. During the refinement process of com-pounding, a variety of dusts and fumes are created that must be reliably extracted.

DuBay Polymer in Hamm-Uentrop annually pro-duces up to 80,000 tons of polybutylene terephthal-ate (PBT). The polymer is the primary component of premium plastics that are utilized in numerous in-dustries because of their flexibility. DuBay was estab-lished in 2001 as a joint venture between LANXESS and DuPont and has been experiencing steady growth in recent years.

Lighter Plastics TrendA driving force behind this development is the current trend toward replacing met-als with durable and versatile high-performance plastics, or utilizing both materials as a composite (hybrid technol-ogy).

“One advantage of plastics compared to metal is the fact that the components are lightweight, resulting in lower fuel consumption, lower costs for the auto-mobile owner and reduced CO2 emissions. A significant advantage for the budget and for the environment,” stresses Michael Pasch, the materials processing engineer responsible for the com-pounding system.

By adding a bulking agent, fibers, and other additives, the PBT polymer achieves certain targeted character-istics in such a treatment process. DuBay employees can produce plastics sturdy enough for use as compo-nents capable of withstand-ing heavy use loads such as hinges, housings, heavy foot traffic, or ease of access de-vices. “Because of their heat

resistance, automotive suppliers also utilize these plastics in components which are subjected to high temperatures, such as headlight mounts,” adds Pasch.

Dual-Stage Separation TechnologyIn the beginning of 2012, DuBay introduced a second compounding system and thereby doubled its capac-ity for high-end plastics. During the planning stages, the system operators requested improvements to the existing labor-intensive extraction process. The key recommendation was provided by Lanxess, the parent company, which has experienced long-lasting results with Keller separators, especially for plastic refinement processes.

The requirements of Pasch and his colleagues are consistent with the two-part filtration technology used by Keller for compounding processes. “First we separate dry dusts created during the weighing, mixing, and addition of additives by utilizing a dry separator. Then, any adhesive aerosols released dur-ing extrusion processes are separated by a wet sepa-rator,” explains Nick Herfurth, vice president of sales and operations at Keller.

Decreased Sludge Facilitates DisposalThere is a frequent risk of deposit buildup and fires inside the ductwork. To offset this risk, Keller employs spray nozzles that rinse the dirty air duct with water over the entire surface. “The evaporative cooling creates a sudden temperature change which results in the condensation of high boiling point solvents,” says Herfurth. The subsequent wet separa-tion removes liquid in addition to solid particulate from the exhaust flow and separates them from the waste water in the sedimentation basin. The result-ing sludge is discharged automatically and continu-ously by a sludge remover and sinks into an adjacent disposal container. “We are pleased that we no lon-ger remove the sludge manually – the operation is now much simpler and a cleaning is seldom neces-sary,” Pasch adds.

“The fact that dust generated at the mixing platforms is extracted by a separate dry separa-tor further reduces the amount of sludge that ac-cumulates in the wet separator,” says Pasch. “This facilitates disposal and is more economical. In ad-dition, the dry separator is very easy to maintain. The filter element cleaning is controlled automati-cally by differential pressure or at pre-set time intervals. Full disposal containers can be emptied during operation. The level monitor indicates – Keller dry separator Vario



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normally after an interval of some weeks – that the container can be emptied.

Dry Separation Process Must Meet ATEX GuidelinesThe requirements of the ATEX guidelines apply to the operation of a compounding system (explo-sion protection guidelines of the European Union). The Vario dry separator is equipped with a high-quality pressure relief valve that can flamelessly absorb any energy created in the unlikely event of an explosion. One of Keller’s pat-ented back pressure flaps can pre-vent the spread of the shock wave and flames into the workplace.

Reliable Filtration Provides System ReliabilityPasch and his colleagues manage the compounding system from their control station. A number of monitors and displays assist them. “We only leave if a mal-function message is displayed and this rarely occurs,” says Pasch. The high reliability not only fa-cilitates the operator’s work, but also boosts the rate of produc-tion. “The separation operates

smoothly nearly without supervi-sion,” says Pasch.

When asked if Keller would be considered for the potential purchase of a third compound-ing system Pasch said, “Keller is one step ahead as far as filtra-tion technology is concerned. Of

course they would be in conten-tion.”

For more information on Keller USA Inc. (Fort Mill, SC), call 803-396-2000 or visit www.kellerusa.com.

High-tech plastics are usually delivered

as granulate.

Volkmann creates high quality,

vacuum conveying solutions

delivering your product

just right, no matter where it

needs to go. Dense phase

vacuum conveying

free of segregation,

damage or abrasion.

609-265-0101 www.volkmannUSA.com

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Screening & Separation

Equipment Zone


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• Storage

Disk-Type Fluidizers

Solimar offers disk-type fluidizers for

the discharge of powders and bulk

solids. This complete line offers long-

wearing aeration devices for many

applications including silos, hoppers,

bins, and trailers. The fluidizers are

particularly effective at preventing

rat-holing and bridging by utilizing air

pressure to move the material while

gently vibrating the vessel wall. The

company’s products are divided into

two distinct application areas. Silo

products include a line of disk aerators that enhance the flow of powders in various

storage devices, and transportation products including disk aerators designed for dry

bulk trailer usage. Features include: superior sealing properties; optimized air volume

to better unload silos or trailers; an original durable design, in two diameters (2 and 4

in.), that will not crack, wear prematurely, or clog like fabric pads; FDA-approved ma-

terials with operating temperatures up to 450ºF; and a metallic detectable version for

food applications.

Solimar Pneumatics, Minneapolis, MN 800-233-7109

www.solimarpneumatics.com

Side Door Bin

Used primarily in the food and

chemical industries for discharging

large volumes of dry products, the

side door bin features a large door

opening that allows product prone

to bridging to discharge quickly and

completely. This new gasket-free

door design makes this container

an even more economical choice

for handling dry materials with op-

tions of stainless, carbon steel, or

aluminum construction, and capaci-

ties up to 100 cu ft. The stackable bins are combined with a discharge

station to automatically tilt bins to 45 degrees.

Custom Powder Systems, Springfield, MO 417-868-8002

www.custom-powder.com

Rolled, Tapered-Panel Tanks

The best features of bolted and field-

welded tank construction have been

combined in the rolled, tapered panel

(RTP) design. Field construction is ac-

complished utilizing a synchronized,

hydraulic screw jack process that keeps

field crews on the ground. This process

receives the highest industry ratings for

quality control and safety in the field.

Tank Connection designs, manufac-

tures, and installs all four types of steel

storage tanks, including bolted RTP,

field-weld, shop-weld, and hybrid tank

designs.

Tank Connection, Parsons, KS

620-423-3010 www.tankconnection.com

Silo Sweep Auger

The new Silo Sweep Auger from Guttridge Ltd is a

robust machine for the automated emptying of grain

silos. Grain silos empty under gravity but as grain lev-

els drop this process stalls. One option is to dig out the

residual volume manually, but this incurs substantial

labor costs and raises HSE issues. The alternative is to

use a sweep auger, which as the name suggests, sweeps

across the silo floor, transferring the remaining grain via

a screw to the silo outlet. The Silo Sweep Auger is made

from galvanized steel to improve longevity and reduce

the risk of product contamination from flaking paint.

Rubber blades ensure an efficient sweep of the silo

floor while an enclosed clutch and motor mechanism

prevents grain ingress and subsequent damage, improving reliability. The patented drive design

delivers the very highest levels of efficiency by reducing slip and strain within the system.

Guttridge Ltd, Pinchbeck, Spalding, Lincolnshire, UK +44 (0) 1775 765 300 www.guttridge.co.uk

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TechnologyReview


ProductFocus

SpaceSaver High-Efficiency

Dust Collector

The SpaceSaver dust collector is up to 75% smaller than tra-ditional dust collectors, offering long-lasting, leak-free cartridges. With a footprint as small as 27 x 38 in., the SpaceSaver is suited for applications with limited space re-quirements in terms of both cross-section and overall height, as well as in areas of the plant that aren’t connected to central dust collec-tion systems. Many cartridge styles are available to best fit the appli-cation, with sizes ranging from 2 to 48 cartridges per collector. The SpaceSaver uses directed air flow fire to pulse the cartridges. Schenck Process, Whitewater, WI 262-473-2441 www.schenckprocessinc.com

Modu-Kleen Downdraft Series

Dust Collector

The Modu-Kleen downdraft dust collector contains fugitive dust. The air enters at the top of the dust collector housing and flows downward to the cartridge filters, improving the filtering process and the material-to-air ratio. Air veloci-ties are lower than those with a conventional dust collector, reduc-ing the load on each filter car-tridge and extending filter life. Dynamic Air Inc., St. Paul, MN 651-484-2900 www.dynamicair.com

High-Temperature Wax Technology for Induction Seal Liners

Tri-Seal has introduced a high-temperature wax technology designed to bolster the stability of two-piece induction seals that are stored or distrib-uted in challenging high-temperature conditions. The solution is specifi-cally engineered to reduce costly (and potentially dangerous) seal-related product leakage from packaging closures. This is a particular cause of concern for lined closures and seals shipped or stored in high-temperature conditions, such as those found in India, Israel, Southeast Asia, Australia, Puerto Rico, and Latin and South America, as well as southern American states and, more seasonally, throughout greater North America. When exposed to high temperatures even for brief periods, the wax component of a two-piece induction seal can be prematurely absorbed into the pulp layer prior to closure application, thereby potentially compromising seal integrity during the filling and capping process. Often, the result is a “potato-chip effect” whereby the heat seal portion of the circular seal’s outer edge curls and separates from the backing material. During capping, the heat seal portion can fold under and not fully seal on the bottle finish. The ensuing leakage is a particular problem for companies who manufacture and distribute highly sensitive or unstable products, such as those found in pharmaceutical, agricultural, chemical, and au-tomotive industries. Tri-Seal, Blauvelt, NY 845-353-3300 www.tri-seal.com

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• Particle Analysis

Morphologi G3-ID Characterizes Discrete Particle Populations within Powder Blends

The Morphologi G3-ID from Malvern Instruments is a powerful particle characterization system that combines

automated imaging with Raman spectroscopy. Using these technologies, it delivers component specific particle

size and shape distribution data for discrete populations within a powder blend. One application is in the analy-

sis of environmentally friendly cements, where a proportion of clinker is replaced with ‘waste’ materials, such

as blast furnace slag or fly ash. For most cements, laser diffraction particle sizing meets routine analysis re-

quirements. However, for cements containing

replacement materials it is often necessary to

measure the particle size of individual compo-

nents within the blended product. Morphologi

G3-ID provides statistically relevant particle

size and shape data for each component, even

where these are morphologically similar. These

data are helping manufacturers optimize the

performance of newer cements and manage development and future production costs.

Malvern Instruments Inc., 508-768-6400 Westborough, MA www.malvern.com

Particle Insight Size and Shape Analyzer

Particulate Systems’ Particle Insight is ideal for ap-

plications where the shape of raw materials – not

just the diameter – is critical to the performance of

the final product. The instrument offers up to 28

different shape parameters analyzed in real-time in

either aqueous or organic solvent suspensions. The

Particle Insight operates in a range suitable for a

wide variety of industrial, biological, and geological

specimens from 1 to 800 micrometers. Its unique

recirculating sample module and precision optics

are designed to acquire and report statistically valid

measurements quickly, an essential quality con-

trol capability in many manufacturing processes.

Particle Insight features include the ability to track

sample shape changes over time as well as the capability to store a collection of particle images.

The user has the option of viewing only those particle images that meet any combination of the

analyzer’s 28 shape parameters. It also has an automated fill-and-rinse feature allowing for true

unattended operation.

Micromeritics Instrument Corp., Norcross, GA 770-662-3688 www.micromeritics.com

www.

.com

Check out our Instrumentation

& Control Equipment Zone

for the latest articles,

equipment, and news


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Scientifc Dust Collectors ofers a FREE second edition publica-tion on dust collection titled “A Scientifc

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v a l v e s , ga t e s , & a i r l o ck s s h o w c a s e

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4Pinch Type Diverter ValveCyclonaire’s pinch type diverter valve is ideally suited for medium pressure (to 85 PSIG) conveying when custom angle divergence or convergence of material flow is required. Double wall construction for long life (even with highly abra-sive material) and obstruction-free flows are standard. These valves are built to exceedingly heavy duty standards for value and performance.

Cyclonaire Corp.www.cyclonaire.com

Long Life ValveThe SD Airlock is designed to seal tight and offer years of life and easy maintenance. It provides tight sealing clearances, hard-to-bend oversized shafts, easy-change bearings, and maintenance-free seals. Try a SD valve and experience why quality makes a difference.

Progressive Products Inc.www.progressiveproductsinc.com

Emergency Slide ValveThe Britton Procol Model VN manual slide valve for dry pow-ders was developed especially to meet the need for an emer-gency slide valve. The slide plate can be fitted with a standard nylon handle for normal pull/push operation or with a striker plate for emergency use. The felt seal around the slide plate is contained in an adjustable stuffing box. The aluminum alloy body and the 304 stainless steel slide plate, running on nylon 66 adjustable supports, permit the valve in its standard form to be used with a wide variety of materials in the chemical, plastics, pharmaceutical, and food industries.

SMS International Inc.www.smsint.com

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Special Advertising Section

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Inflatable Seated Butterfly ValveAn inflatable seated butterfly valve designed for dry bulk solids or liquid slurry applications is available from Posi-flate. The valve is ideally suited for abrasive materials such as sand, feldspar, fly ash, and most other dry, granular materials, which reduce valve life. The inflatable seat design pro-vides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. Standard sizes range from 2 in. (50 mm) to 30 in. (750 mm). The valves are available in a wide variety of construction materials including stainless steel and lightweight aluminum.

Posi-flatewww.posiflate.com

Series “A” Maintenance GatesMaintenance gates from Lorenz are used for mounting above airlocks or below bins and hoppers that require periodic shut-downs for maintenance of dry material. Lorenz maintenance gates can be used in dilute phase, vacuum, and gravity appli-cations. Constructed with fully lined polymer liner and clear covers are standard. Available in hand crank, hand wheel, or chain wheel actuation. Features include a narrow profile and lightweight aluminum frame construction. Constant pressure woven Teflon seals are on the polished stainless steel blade. Rated up to 110ºC (230ºF). Manufactured in square or round configurations.

Lorenz Conveying Products Corp.www.lorenzproducts.com

New Pneumatic Conveying Component BrochureIntroducing the new catalog of pneumatic conveying components from Pelletron Corp. This catalog includes a comprehensive overview of the com-ponent program, consisting of rotary valves and diverter valves for pellets and powders, the complete DeDuster product line, cyclones, dust collectors, shut-off valves, pipe supports, Pellbow pipe bends, and other equipment. The catalog provides necessary information for both replacement of com-ponents in existing plants and the design of new conveying lines. Pelletron engineers are available to provide design and layout support for unique applications and to assist with the selection of suitable components.

Pelletron Corp.www.pelletroncorp.com

Have a question?

Ask our Experts at


www.

.com

Check out our

Valves, Gates, & Airlocks

Equipment Zone

for more articles and news headlines at


Low Cost Alternative to Rotary Airlock ValveAerodyne’s Vacu-Valve is one of the lowest-cost, lowest-main-tenance dust collector valves available. The Vacu-Valve comes in two designs; both the open-construction of the Platypus and the closed construction of the Armadillo offer a cost effective alternative to rotary valves in certain applications. A vacuum operated valve is suitable for continuous discharge applications that have dense, free-flowing material such as sand, coffee grounds, as well as other industrial particulate. This trickle valve system operates as a constant discharge valve for dust collectors, hoppers, and other pollution control equipment operating under negative pressure. Its unique bill design allows it to dispense free-flowing material continu-ously.

Aerodyne Environmentalwww.dustcollectorhq.com

Slide Rail System for Easi-Clean Tapered Rotary AirlockThe Bush & Wilton Easi-Clean tapered rotary airlock is now offered with a slide rail system. With this design, the slide rail system will support the rotor and end cover upon removal, while incorporating the Easi-Clean system which allows for rotor removal without disconnection of the drive. In addition, this rotary airlock contains the Bush & Wilton tapered rotor feature which allows for rotor clearance adjustment in the field to compensate for temperature, wear, or product variations. This rotary airlock would typically be used in food or sanitary applications, where the valve’s internals need to be cleaned on a regular basis. Also, it can be used in applications that require frequent product changeover.

Bush & Wilton Inc.www.bushandwilton.com

Rotary Valves Deliver High Performance Feeding RVS-type blow-through rotary valves have been developed in accordance with the criteria of meeting a maximum scope in application. They have been designed for the controlled discharging of powders or granular materials from silos, bins, hoppers, cyclones, or dust collectors into low- and medium-pressure pneumatic conveying lines. RVS blow-through rotary valves consist of a tubular cast iron or stainless steel casing, a horizontally mounted rotor with a defined number of oblique V-shaped cross section compartments, a drive unit, and a casing cover at each end. To provide long-term, heavy-duty feeder performance with differ-ent materials, numerous rotor and body surface treatments such as nickel plating, Teflon coating, and hardened chromed plating can be provided.

WAM Inc.www.waminc.com


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www.PowderBulkSolids.com 37ClassifiedDirectory

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We sell your equipment, find that talented job applicant, and bring your consulting service to the industry decision maker.

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EQUIPMENT & MATERIALSCUSTOM SERVICES

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AdvertiserIndex

For complete board member bios, visit www.PowderBulkSolids.com

Airlanco .................................................19www.airlanco.com

Bunting Magnetics Co. .......................16www.buntingmagnetics.com

Bush & Wilton .......................................34www.bushandwilton.com

C&W Manufacturing and Sales Co. ....22www.cwmfg.com

Camfil Air Pollution Control .................4,5www.camfilapc.com

Clarcor Industrial Air .............................11www.clarcorindustrialair.com

Control Concepts Inc. .........................23www.airsweepsystems.com

Custom Equipment Design ..................27www.cedpackaging.com

Cyclonaire Corp. ..................................17www.cyclonaire.com

Dynamic Air Inc. ....................................2www.dynamicair.com

Fike .......................................................31www.fike.com

Flexicon Corp. ..................................9,40www.flexicon.com

FPZ Inc. ................................................33www.fpz.com

GreCon Inc. ..........................................33www.grecon-us.com

Hammertek Corp. ................................31www.hammertek.com

Industrial Magnetics Inc. .....................12www.magnetics.com

JOA North America LLC.......................32www.joa-nam.com

Kuriyama of America Inc. ....................12www.kuriyama.com

Litco International .................................21www.litco.com

Lorenz Conveying Products .................26www.lorenz.ca

Material Transfer & Storage ..................23www.materialtransfer.com

Meese Orbitron Dunne ...........................8www.shipshapecontainers.com

Monitor Technologies LLC ...................29www.monitortech.com

National Bulk Equipment Inc. ...............3www.nbe-inc.com

Nol-Tec Systems Inc. ..........................10www.nol-tec.com

Paul O. Abbe ..........................................8www.pauloabbe.com

Pelletron Corp. .....................................15www.pelletroncorp.com

Progressive Products Inc. ...................26www.progressiveproductsinc.com

REMBE GmbH Safety + Control ..........17www.rembe.de

Roto-Disc Co. ......................................29www.rotodisc.com

Scientific Dust Collectors .....................34www.scientificdustcollectors.com

Sifter Parts & Service Inc. ...................17www.sifterparts.com

Sioux Steel ............................................12www.dustsuppressionhopper.com

SMICO Manufacturing Company, LLC ....

...............................................................33www.smico.com

SMS International Inc. .........................21www.smsint.com

Spiroflow Systems Inc. ..........................7www.spiroflowsystems.com

The Pivotal Edge...................................22www.thepivotaledge.com

Vac-U-Max ............................................13www.vac-u-max.com

Volkmann ..............................................31www.volkmannUSA.com

Editor-in-ChiefKevin Cronin973-786-6401 • [email protected]

Managing EditorJoe Florkowski310-445-4276 • [email protected]

PROMOTIONS, ART, & PRODUCTION

Marketing ManagerClem [email protected]

Creative DirectorMarco Aguilera

Associate Art DirectorPrakash Barnabas

Publications Production DirectorJeff Tade, [email protected]

Publications Production ManagerVenkatraman Jayaraman

CIRCULATION/SUBSCRIBER SERVICE

Circulation ManagerXavier Contaoi, [email protected]

KMPSBox 47461, Plymouth, MN 55447Phone: 800-869-6882; Fax: [email protected]

ADVERTISING REPRESENTATIVES

AZ, AK, CA, CO, HA, ID, LA, MT, NM, NV, OK, OR, TX, UT, WA, WY; in Canada, BC, AB, SKTony Marsh, Brand Director 310-445-3725 • [email protected]

IA, IL, IN, KS, MI, MN, MO, NE, ND, SD, WI; in Canada, ON, MBKay Christensen651-388-0014 • [email protected]

AL, AR, CT, DE, FL, GA, KY, MA, ME, MD, MS, NH, NC, NJ, NY, OH, PA, RI, SC, TN, VA, VT, WV; in Canada, QC, NB, NLTim Savage860-267-6297 • [email protected]

Classified AdvertisingBeth Berner440-209-1478 • [email protected]

List RentalsStatlistics, 203-778-8700

Postal ListsJennifer Felling, [email protected]

E-ListsTurk Hassan, [email protected]

Wright’s Media877-652-5295 • [email protected]

CORPORATE OFFICEUBM Canon2901 28th St., Suite 100Santa Monica, CA 90405 USAPhone: 310-445-4200; Fax: 310-445-4299

Executive Vice President/Managing DirectorJosh Dome

Senior Vice President, Content & StrategyPam Moore

Vice President/ Design & Manufacturing Portfolio DirectorRoger Burg

Senior Vice President, Integrated MediaAmy Sklar

Vice President, DirectoriesTim Simone

Volume 32, No. 9

The Advertiser Index is provided as a reader service. Although every attempt has been made to make this index as complete as possible, the accuracy of

all listings cannot be guaranteed.

Manage Your SubscriptionFor fast and easy subscription services, go to

www.powderbulksolids.com and click on Free Subscription.

• Renew your subscription • Sign up for a new subscription

• Change your address • Cancel your subscription

For all other customer service inquiries, call 763-746-2792, or e-mail to [email protected].

Virendra M. Puri, PhDProfessorPenn State University

Remi Trottier, PhDSenior Specialist —Particle CharacterizationThe Dow Chemical Co.

Eric P. Maynard, MSMESenior ConsultantJenike & Johanson Inc.

Don McGlinchey, PhDReaderGlasgow CaledonianUniversity, Scotland

Giuseppe BonifaziFull Professor of RawMaterials BeneficiationUniversity of Rome, La Sapienza

David Mills, PhDPneumatic ConveyingConsultant

Dilip M. ParikhPresidentDPharma Group Inc.

Vahid Ebadat, PhDCEOChilworth Technology Inc.

John R. Pugh, PhDHead of Centre for Industrial Bulk Solids HandlingGlasgow CaledonianUniversity, Scotland

Rick WynnVice PresidentWynn Environmental Sales

M. G. Jones, PhDHead, School of EngineeringUniversity of Newcastle,Australia

Ashok Ghose Dastidar, PhD Vice PresidentFauske & Associates Inc.

Editorial Advisory BoardPowder & Bulk Solids® (ISSN 8750-6653, USPS 733-550) is published monthly with a special spring issue by UBM Canon, 2901 28th Street, Suite 100, Santa Monica, CA 90405. Periodicals mail postage paid at Santa Monica, CA 90405 and at additional mailing offices.

SUBSCRIPTIONS: Free to qualified subscribers as defined on the subscription card. Basic subscription price $150 (one year). Delivery outside the United States by air service. The Powder & Bulk Solids® Industry Master is available for $95 plus shipping and handling.

CHANGE OF ADDRESS: Send change of address and cor-respondence concerning subscriptions to Powder & Bulk Solids®, P.O. Box 47461, Plymouth, MN 55447 or [email protected]. For telephone inquiries regarding sub-scriptions, call 763-746-2792. Change of address notices should include old and new address. Allow 8 to 10 weeks for address change to become effective.

Opinions expressed in articles are those of the authors and do not necessarily reflect those of UBM Canon or its editors. The editors make every reasonable effort to verify the information published, but UBM Canon assumes no responsibility for the validity of any manufacturers’ claims or statements in items reported. UBM Canon does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. Printed in U.S.A.

Powder & Bulk Solids® is a registered trademark of UBM Canon. Copyright 2014 by UBM Canon. All rights reserved under the United States, Inter national, and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, electronic recording, or otherwise without the prior written permission of the publisher.

POSTMASTER: Send return address changes to Powder & Bulk Solids®, P.O. Box 47461, Plymouth, MN 55447. Return undeliverable Canadian addresses to APC Postal Logistics LLC, P.O. Box 412, East Rutherford, NJ 07073-0412.

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Give your next pneumatic conveyor the PNEUMATI-CON® advantage:

CC

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©2014 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

*Patent(s) granted and/or pending.

CHILE

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AUSTRALIA

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It takes more than a great pneumatic

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Convey free- and non-free-flowing bulk materialsBEV-CON™ Conveyors transport

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Elevate, tip and dischargeboxes/containers dust-freeTIP-TITE® High-Lift Box/Container

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Convey fragile products gentlyover short or long distancesFLEXI-DISC™ Tubular Cable

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Single or multiple inlets and outlets can be added, removed or

relocated, and the circuit lengthened, shortened or re-routed

as needs change. Stand-alone units to automated systems

integrated with new or existing process equipment—to sanitary

or industrial standards.

Load/unload and condition bulkbags on all sides at all heightsBLOCK-BUSTER® Bulk Bag

Conditioner features a hydraulically

actuated, variable-height turntable

for automated in-frame bag

rotation and conditioning of bulk

bags at varying heights. The

number and pressure of hydraulic

ram actuations, the height of

the turntable, and the degree of

rotation are user-programmable.

Two hydraulic rams with specially

contoured conditioning plates

press opposing sides of bulk bags, loosening material that has

solidified during storage and shipment, enabling bulk bag

unloaders to discharge it through bag spouts. Cantilevered

I-beam with motorized hoist and trolley allows loading and

unloading of bulk bags without using a forklift.

Dispense and position pallets automaticallyFLEXICON® Pallet Dispenser

with Powered Roller Conveyor

automatically dispenses and

positions pallets, significantly

improving safety and efficiency

over manual methods. Accom-

modates 40 x 48 in. and 42 x

48 in. (102 x 122 cm and 107

x 122 cm) pallets and non-

standard sizes. Dispenser forks

lower the pallet stack onto the

roller conveyor, withdraw from

the bottom pallet, and raise the

remaining pallets, allowing the conveyor with photoelectric

sensors to position it. Audible signal and/or flashing light indicate

low pallet level. Easily integrated into palletizing/filling systems

for drums, pails, bulk bags, sacks and other containers/packages.

Unload bulk bags and rigidbins in low headroom areasFLEXICON® Low Profile Split

Frame Unloader allows discharg-

ing of bulk bags and rigid bins

from mezzanines and other low

headroom areas. Upper frame can

be forklifted onto plant floor, loaded

with a bulk bag, and then forklifted

back onto the sub frame within

several inches/centimeters of the

ceiling. A POWER-CINCHER® flow

control valve* cinches the bag

spout concentrically, preventing

uncontrolled bursts of material

from the bag, and allowing leak-free retying of partially empty bags.

For unloading of bulk solids from rigid bins, the bins are fork-

lifted onto receiving cups of the sub frame, and seated against

a flanged chute discharging into a vessel below the mezzanine.

As importantly, you will find experienced

process engineers who draw on Flexicon’s

20,000+ installations integrating conveyors,

screeners, grinders, crushers, blenders,

weigh hoppers, bulk bag unloaders/fillers,

bag/drum dump stations, and/or storage

vessels—experts who understand how your

upstream and downstream equipment can

impact, and be impacted by, the operation

of your pneumatic conveyor.

Going the extra distance to outperform

competitive pneumatic conveyors is what

the PNEUMATI-CON® advantage is all about.

It’s what enables Flexicon to guarantee top

results, and you to make pivotal improvements

to your process with absolute confidence.

