Conveying difficult-to-move materials can be very time-consuming; negatively affecting the profitability of your business. Additionally, having operators attempting to manually agitate or introduce material into a processing line significantly increases the potential of operator injuries. In this month’s Application Spotlight, we share a recent solution we engineered to introduce a granular, non-free-flowing, elastomer into a negative pressure dilute phase pneumatic conveying system from gaylord boxes. Check out the video below!
Utilizing a Reliant Container Dumper positioned on a riser stand we were able to fully discharge a complete gaylord of the rubber-like elastomer into our High-Capacity Live Bottom (HCLB) Bin. The HCLB bin was engineered with a horizontal agitation shaft specifically designed to condition the material prior to the discharge auger dosing the material into the downstream conveying system. Although the controls of the Reliant Dumper and HCLB bin were isolated from each other to permit the portability of the HCLB bin, the HLCB Dumper was equipped with a variable speed controller (VFD), and open interlock contacts. This enabled the processor to dial in the feed rate to their specific needs and integrate easily into the conveying controls so that material was only fed when demand for the material was required.
Difficulties With Conveying Elastomers or Flexible Materials
Elastic or rubber-like materials like the one specified in this application present an intriguing material handling dilemma, particularly when using screw conveyors. When a screw conveyor engages, the flights of the auger begin to turn, pushing against the material. When an auger speed demand is required to be at an instantaneous high RPM, the pressure against material can be quite abrupt. In applications using materials such as described in this project, the elastomer’s rubber-like inhibits the granules from sliding or flowing around one another and the surface of the auger. The flexible materials actually compresses against itself instead, which results in the absorption of the torque force applied to the auger from the drive train assembly.
Overcoming torque absorbing material, cost-effectively, requires two key items. An oversized, high-torque, drive train assembly and a Variable Frequency Drive (VFD). The VFD can begin rotating the screw conveyor slowly at first, later ramping up to a full throughput RPM level. This will significantly decrease the torque demand required from the motor/gear drive configuration as it gives slightly more time for the material to begin to gain movement and flow out of the discharge point. Accompanying a VFD should be a high-torque motor/gearbox drive assembly properly specified for the type of material being conveyed. Not all rubber or flexible materials will react in the same manner. Consulting Ensign’s team of engineers, and leveraging our more than 30years of system installments will allow you to use the right solution for the material you are working with.
Available Options for Ensign’s Dumpers & High-Capacity Live Bottom Bins
Ensign’s extensive library of available options gives you the flexibility to address almost any material handling challenge. And with robust designs that are built to last, we can put your team in a position to succeed for years to come.
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