Pneumatik 0311 En
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Pneumatic Conveying
2altmayerBTD GmbH & Co. KG is the right partner for system, bin, energy and environmental technolo-gy. Our tradition-rich companys product portfolio ranges from bin and reservoir technology to heating
and drinking water systems and solar technology, to storage and transport of bulk solids.
Pneumatic conveying allows bulk solids to be transported simply and hygienically through pipelines.
The right choice of a conveying system is based on many different criteria and is the prerequisite for the
systems operational safety, energy efficiency and cost effectiveness.
Regardless of whether universally applicable air conveying or sophisticated dense-flow conveying is
adopted, the product line offered by altmayerBTD GmbH & Co. KG has the right system for every con-
veying process.
Our decades of experience in this field are the best guarantee of sophisticated expertise and process
reliability.
As a result of our own production, experienced engineers and installation and service technicians, we
guarantee maximum customer benefit combined with innovative, efficient technology.
Pneumatic Conveying
AIRDOS
AIRDOS
Continuous Gravimetric Metering with Direct Input of Material into Pneumatic Conveying Systems
The increasing quality demands on technological processes require metering devices that, during mete-
ring, offer optimal conditions when it comes to metering accuracy, operational safety, compact construc-
tion and simple operation and maintenance. If, in addition, direct product feed into pneumatic conveying
systems is necessary, the AIRDOS metering system offers the required characteristics at the same
time.
Benefits
Pulsation-free metering
High short- and long-term accuracy
Not affected by taring changes; no taring adjustment
Dispensing results independent of the devices feed conditions and the solids flow
characteristics
High control dynamics
Pre-homogenization of the solid in the fluidized bed
Increased control range through multi-flow conveying to a single receiver
Energy savings with pneumatic transport through multi-flow conveying to a single
receiver
Closed system, dust-proof exterior, suitable for transferring inert gases
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Pressure-shock-resistant design
Direct integration into a pneumatic conveying system
Leakage air does not affect the pneumatic transport system
Trouble-free product discharge of fluidized solids from the metering disk
Low energy consumption
Designed for easy service
Modular construction
No uncontrolled product entry into the feed pipe
Precise volumetric dispensing through constant fluidized bed tightness
Optional batch operation with pre-homogenization
Optional pneumatic feed to the AIRDOS dispensing system
Operation
Fluidization of the solids through the AIRDOS metering systems aeration floor causes a homogeneous
fluidized bed that possesses liquid-like characteristics. The metering disk is completely immersed in the
homogeneous fluidized bed and has several coaxial hole circles with bores that determine the metering
volume. As a result of the liquid-like characteristics of the fluidized bed, the bores fill completely with the
solid to be metered. By the rotation of the disk around the horizontal axle of the metering disk drive, the
solid is moved through two slide ring seals and fed into the pneumatic feed pipe.
Metering is pulsation-free because at any given time of the disks rotational movement, the same number
of metering holes is immersed into the feed pipe. The type of slide ring seals used limits the amount of
leakage air and effectively prevents uncontrolled entry of material into the feed pipe. The mixing of an in-
homogeneous solid accumulating in the fluidized bed, the complete filling of the metering disk bores and
the constant density of the solid in the fluidized bed are the reasons for the constant, pulsation-free mete-
ring with an almost linear relationship between driving speed and dispensing performance. Therefore, the
AIRDOS metering system can also be used in many ways as a volumetric operating device.
When the minimum fill level is reached, the device is filled through the filling nozzle to the upper fill
level. The displaced air as well as the fluidization air and the leakage air are discharged into atmosphere
through an integrated filter that is cleaned by compressed air. Multi-flow designs of the conveyor tube
arrangement are used to increase the metering performance.
In that case, the blow-through openings on the metering disk have the same distance from each other. If
the lines outside the AIRDOS metering system are brought together again, the metering performance
increases according to the number of blow-through openings.
AIRDOS
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If the pipelines are not brought together, two separate processors can be fed with the same or propor-
tional output. If separate pipelines are brought to one processor, allocation of the maximum metering out-
put into sub-quantities and a corresponding adjustment of the amount of conveying air allow a significant
increase in the metering control range. At the same time, adjusting the amount of conveying air to the
metering performance allows considerable energy savings.
In the case of gravimetric dispensing, the AIRDOS dispensing system works according to the principle
of a loss-in-weight feeder. Continuous determination of the weight loss per time unit allows determination
of the metered quantity. After the metered quantity is compared to the pre-set reference quantity, the con-
trol variable for the subordinate control circuit of the metering disks drive motor is established.
During the short refilling phase, the AIRDOS metering unit is switched over to volumetric metering
operation. Variations from the gravimetric operation in this phase are barely measurable as a result of the
operation with fill-level-dependent RPMs that have been stored during gravimetric operation.
1 Weighing frame 2 Aeration floor 3 Aeration blower 4 Bin 5 Metering disk 6 Metering disk drive 7 Conveying air inlet 8 Product outlet 9 Level sensor10 AIRDOS controller 11 Filling nozzle 12 Filter 13 Sight glass 14 Butterfly valve
AIRDOS
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Principle of the loss-in-weight feeder Weight loss per time unit
Structure and Designs
The simple, compact structure that is independent of additional equipment allows installation also in
existing systems. AIRDOS metering devices come standard in a pressure-shock-resistant design for
pressure of 10 bar.
The solids are fluidized by an adjustable side channel blower above a sintered metal floor. The metering
disk is driven by a frequency-controlled three-phase motor. The metering disks very low friction against
the fluidized solids allows low drive powers. The metering disks low moment of inertia makes possible
high control dynamics that can be seen in the AIRDOS metering systems extremely short response time
to changes of the reference value.
Using a highly wear-resistant material for the metering disk and slide ring seals easily allows a lifetime of
several thousand operating hours, depending on the solids. As a result of the resilient mounting of the
slide ring seals on the metering disk, reworking of the disk is possible even after longer operating periods.
The leakage air occurring with every air lock system is extremely low. It amounts to about 5% of the leak-
age air of a new rotary feeder, but the resilient seal keeps it constant even after long operating periods.
All seals and bearings of the drive shaft are accessible from outside. The interior of the AIRDOS metering
system can be monitored constantly through the two sight glass openings. If necessary, the metering disk
and slide ring seals can be removed easily through these openings. The built-in, compressed air acti-
vated cartridge filter cleans the air displaced during filling and discharges it into the atmosphere.
AIRDOS
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Butterfly valves on the conveying air side allow alternative or simultaneous operation of several feed
pipes. The AIRDOS metering unit can be filled through a downpipe or pneumatically, as desired.
The pressures necessary for safe operation of the metering system, such as delivery pressure, bottom
aeration pressure and differential filter pressure, are displayed both in analogue and digital form. The
AIRDOS metering unit can optionally be built in standard or stainless steel. For coarse-grained solids
that are difficult to fluidize, a special design of the AIRDOS metering system is available. As a measure-
ment, control and regulation system, the AIRDOS controller is based on modern technology. It is dis-
tinguished by its compact, modular construction, flexibility and robust design. Use of the loss-in-weight
system allows metering independent of possible taring changes due to fouling or caking.
Due to the loss-in-weight systems working principle, an upstream silo fill level or the type and design of
the filling pipe has no influence on the quality of the metering result. If several AIRDOS metering systems
are set up underneath a silo, using a ROTAFLOW solids activator is recommended. The AIRDOS me-
tering system is internationally patented.
AIRDOS with ROTAFLOW solids activator
AIRDOS
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AIRDOS double metering system
Application Samples
Coal dust metering for rotary kilns, hot gas generators, drying drums, lime shaft kilns and
tunnel kilns
Metered absorbent input and activated carbon input for dry flue gas cleaning
Metered fly ash input and clinker powder input in cement mills
Metering of copper concentrate into a burner
Metering of a lime-carbon mixture into a fluidized bed boiler
Metering of cleared ash into a burner
Metering of coal dust into a metal bath
Technical Data
Metering capacity range: 0.01 to 30 t/h
Gravimetric long-term accuracy: +/- 0.5% to 1%, based on the actual value in the metering range 1:20
Volumetric long-term accuracy: +/- 1.5% to 3%, based on the actual value in the metering range 1:20
Control range: max. 1:20 with one pipe to a single receiver
Max. temperature of solids: 120C
Max. conveying pressure: 1.8 bar (abs) in the standard design
AIRDOS
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AIRDOS C
AIRDOS C
Continuous Conveying with Direct Input of Material into Pneumatic Conveying Systems
The increasing quality demands on technological processes require conveyor devices that, during con-
veying the solids, offer optimal conditions when it comes to operational safety, compact construction and
simple operation and maintenance. If, in addition, direct product feed into pneumatic conveying systems
is necessary, the AIRDOS C conveying system offers the required characteristics at the same time.
Benefits
Pulsation-free conveying
Conveying results independent of the devices feed conditions and the solids flow
characteristics
Increased conveying range through multi-flow conveying to a single receiver
Energy savings with pneumatic transport through multi-flow conveying to a single receiver
Closed system, dust-proof exterior
Direct integration into a pneumatic conveying system
Leakage air does not affect the transport system
Low energy consumption
Designed for easy service
Modular construction
No uncontrolled product entry into the feed pipe (no risk of clogging)
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Operation
The metering disk is completely immersed in the bulk material and has multiple coaxial hole circles with
bores that determine the metering volume. As a result of the solids gravitational force, the bores fill com-
pletely with the solid to be conveyed.
At the same time, an agitator contributes to a steady discharge of solids. By the rotation of the disk around
the vertical axle of the metering disk drive, the solid is moved through two slide ring seals and fed into the
pneumatic feed pipe.
Conveying is pulsation-free because at any given time of the disks rotational movement, the same num-
ber of metering holes is immersed into the feed pipe. The type of slide ring seals used limits the amount
of leakage air and effectively prevents uncontrolled entry of material into the feed pipe. The conveying
output is almost linearly dependent on the metering disks driving speed.
1 Bin 2 Metering disk 3 Metering disk drive 4 Conveying air inlet 5 Product outlet 6 Level sensorr 7 Filling nozzle 8 Filter 9 Sight glass 10 Hand lever valve 11 Check valve 12 Agitator
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AIRDOS C
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1 Bin 2 Metering disk 3 Metering disk drive 4 Conveying air inlet 5 Product outlet 6 Level sensorr 7 Filling nozzle 8 Filter 9 Sight glass 10 Hand lever valve 11 Check valve 12 Agitator
Technical Data
Conveyor output range: 0.1 to 60 t/h
Control range: 1:20 with one feed pipe
Max. temperature of solids: 120C max.
Conveying pressure: 1.8 bar (abs) in the standard version
Drive power: 3 to 7.5 kW
Three different sizes are available.
Multi-flow design available.
Typical Solids and Applications
Industry Solid
Cement industry Raw coal, petroleum coke, cement, clinker, gypsum, marl, clay,
slag sand
Rocks and soils Cement, gypsum, limestone, marl, silica sand
Power plants Fly ash, ground limestone, hydrated lime, furnace ash
Steel industry Blast furnace slag, raw coal, coke, bauxite
Aluminium industry Foundry sand, aggregates
Waste incineration plants Ash, slag
Chemical industry Plastic, granules, chalk, titanium dioxide
Water treatment Ground limestone, hydrated lime, activated carbon
Glass industry Aggregates, sand, glass batch
AIRDOS C
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CONTIPULS / CONTIDENSE
CONTIPULS / CONTIDENSE
Gentle Pneumatic Dense-Phase Plug Flow Conveyor
The CONTIPULS pneumatic dense-
phase plug flow conveyor works with
plugs.
As a result of selectively clocked air
injections into the feed pipe, the pro-
duct is slowly, gently conveyed as
plugs. These plugs remain compact
until the end of the conveying pipe.
The CONTIPULS system can be re-
gulated well and is suitable for cohe-
sive, powdery products.
The CONTIPULS can also be used for
fine and coarse granulates. Advan-
tages of the CONTIPULS include high solids to air ratios and gentle conveying at a low speed of about
1-5 m/sec. In case of mixtures, segregation-free conveying is guaranteed.
For products that are difficult to convey with a tendency for plug slowdown in the pipeline,
the CONTIPULS system is equipped with pulsating activator groups. The activator groups are installed
only at critical places in the pipeline. The so-called critical plug length is measured, and if the plugs have
reached this critical length, they are cut into smaller pieces. This provides gentle conveying for products
that cannot be conveyed with plug flow conveyors.
Air velocity
Pre
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Plug flow conveying
Bed flow conveying
Dilute-phase conveying
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CONTIPULS Plug Flow Conveying
Benefits of the CONTIPULS System
Gentle plug flow conveying
Low gas consumption
Filter and compressor stations with smaller dimensions
Sensitive products are not destroyed
Abrasive products cause barely any tube wear
Segregation-free movement of mixed materials
Long life, because there are no rotating parts
Low investment, operating and maintenance costs, good total cost-effectiveness
Single and double vessels1 Material feed2 Clocked conveying air3 Closing flap4 Fill level limit switch5 Pressure vessel6 Outlet elbow7 Conveying pressure manometer with pres- sure switch8 Load cells9 CONTIDENSE controls
Fields of Application:
Plastic granulates up to 300 m and 100 t/h Sensitive, coated products
Metal dust mixtures Abrasion free plug flow conveying of sand
Sugar conveying, gentle up to 100 m Conveying of various metal oxides
Sewage sludge granulate Cocoa beans and instant products
Sulphate and carbonate Various chemical products
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CONTIDENSE Dense-Phase Conveying
Benefits of the CONTIDENSE System
Safe dense-phase conveying, the conveying pressure can be raised as desired
High solids to air ratios, reasonable gas consumption
Long conveying lines are possible
Tubes do not need to be purged
Long life, because there are no rotating parts
Can be upgraded to gravimetric metering
Low investment, operating and maintenance costs, good total cost-effectiveness
Single and double vessels 1 Material feed 2 Clocked conveying air 3 Closing flap 4 Fill level limit switch 5 Pressure vessel 6 Outlet elbow 7 Conveying pressure manometer with pressure switch 8 Load cells 9 CONTIDENSE controls
Fields of Application:
Lignite dust up to 400 m
Pressure-shock-resistant systems with silos for lignite dust, sugar, etc.
Cement and filter ash dense-flow systems
Potato starch and corn starch up to 400 m
Carbonates and metal oxides
Aluminium oxides and titanium oxides
Various chemical products
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Operation
The continuous feeding of the solids into the feed pipe happens without rotary motion. This process is
gentle to the product and low on wear. If in the left pressure vessel of the CONTIPULS or CONTIDENSE
the minimum fill level is reached, the outlet valves are gently opened or closed. This allows switching
between the two sending vessels without pressure loss.
For gravimetric metering tasks, the CONTIDENSE can be produced in a double or single version with ad-
ditional rotary feeders instead of the outlet valves. In that case, the pressure vessels are set on load cells.
As a result of the metered product discharge, several CONTIDENSE double vessels can load a common
pipeline. This allows conveying lengths up to 1,000 m.
Structure and Designs
The CONTIPULS and CONTIDENSE pneumatic conveyors come in single and double versions in various
sizes from 20 to 4,000 litres. The pressure range is 4 10 bar. They are produced in standard steel and
stainless steel for the food industry. A large number of our systems were realized using our algorithm de-
sign method. It allows the systems to be calculated with great certainty without conveying tests. The gen-
tle CONTIPULS process thus has an output limit from 0.5 to 120 t/h and conveying lengths up to 300 m.
The CONTIDENSE process has an output limit from 1 to 150 t/h and conveying lengths up to 1,000 m.
CONTIPULS CONTIDENSE
conveys fills
CONTIPULS / CONTIDENSE
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MONODENSE mobile unit
MONODENSE
Variable Pneumatic Transport in Your Plant
The MONODENSE mobile unit was developed to ful-
fil various conveying tasks with one device. For this
purpose, the pneumatic conveyor is built on a roller
frame. This makes it easy to transport the MONO-
DENSE mobile unit to the production area where it is
currently needed.
The device is built completely ready to run and has
its own controls, so that only power and compressed
air connections are necessary to put it into operation
in a new location.
Its technical equipment allows a variable application
range for dilute- and dense-phase conveying. For
customers whose production lines are quite varied,
we offer the possibility to store the various product-
specific settings in the controls, and when nece-
ssary call them up automatically through the control
elements.
Benefits
Variable range of applications for dilute- and dense-phase conveying
High solids to air ratios with low compressed air consumption
Long life, because there are no rotating parts
Low investment, operating and maintenance costs
Ready to plug in, with its own controls
Only power and compressed air connections are needed
Structure and Designs
The MONODENSE mobile unit comes in various sizes from 300 to 1,000 litres (or in even bigger cus-
tom-built sizes). The pressure range is from 4 to 10 bar, so that output from 0.5 to 25 t/h and conveying
lengths up to 150 m can be covered.
Conveying lengths: 40-150 m
Conveying outputs: 1-25.3 m3/h
Temperatures: up to 200C
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INJECTOR CONVEYOR
INJECTOR CONVEYOR
Safe Feeding of Material into Pneumatic Pressure Conveying Systems
Feeding material into the conveying flow of pneumatic pressure conveying systems requires feeders that
overcome the pressure difference between delivery pressure and the pressure of the material feed bin.
The INJECTOR CONVEYOR should be used particularly with hard-to-handle solids, such as long-grained,
abrasive, cohesive or hot materials.
Benefits
No mechanically moved parts
Continuous material feed
Low maintenance cost
Low space requirement
Use in high temperature zones
No leakage air discharge
Dust-free operation
Support of the material feed at the air lock chamber
OperationNarrowing of the propellant nozzles cross-section turns the pressure of the conveying air into kinetic
energy. This generally causes a pressure in the air lock chamber that is below the ambient pressure.
The vacuum draws the conveyed material and a supplementary quantity of air out of the material feed
area, accelerates it and feeds it into the conveying pipe without an additional mechanical seal. The sub-
sequent deceleration of the air flow in the mixing tube creates a static pressure. The acceleration of the
conveyed material in this area reduces the pressure increase.
In the diffuser, the air speed to the feed pipe is decelerated. This increases the pressure up to the end
of the INJECTOR CONVEYOR to the feed pipes operating pressure.
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INJECTOR CONVEYOR
Structure and Designs
The INJECTOR CONVEYOR has no mechanically moved parts and low maintenance requirements. The
geometric dimensions depend on the material load, the material characteristics, the material flow rate and
the feed pipes operating pressure.
Exact knowledge of the INJECTOR CONVEYORs functional contexts and of the pneumatic conveyor sys-
tem allows optimal dimensioning to the specific application. The INJECTOR CONVEYOR can optionally
be built in standard or stainless steel. For abrasive materials, the mixing tube is supplied with a collecting
nozzle and diffuser as a replaceable ceramic insert. For solids that tend to adhere or crust onto the pipe
walls, the special version of the INJECTOR CONVEYOR ring nozzle shall be used.
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1 Material feed 2 Conveying air supply 3 Propellant nozzle 4 Air lock chamber 5 Aeration bottom 6 Nozzle pressure manometer 7 Aeration pressure manometer 8 Collecting nozzle 9 Mixing tube 10 Diffuser11 Conveyor pressure manometer
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INJECTOR CONVEYOR
Applications
Dusty or granular solids
Conveying capacity up to 15 t/h
Conveying distance up to 200 m
Solids to air ratio below 5
Sample applications
Filter ash removal
Fluidized bed boiler coatings with hydrated lime
Absorbent input for dry flue gas cleaning
Powdered coal firing systems
Activated carbon input in waste incineration plant gas lines
Transport of returns in packing systems
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Pressure gain in relation to the dynamic pressure of the propulsion jet
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Sub
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altmayerBTD GmbH & Co. KGHeadquarters: System technology: Representatives: Brckenstrae 1 Sdstrae 14 Santa Sanayi Mamulleri TIC. Dearborn Mid-West Conveyor Co.72135 Dettenhausen 66780 Rehlingen ve San. Ltd. Sti. 4220 Shawna Mission Parkway Germany Germany Ankara/Turkey Suite 301 BTel.: +49 (0) 71 57 5 62-0 Tel.: +49 (0) 68 35 91 93-0 Tel.: +90 3 12 3 42 52 50 Fairway KS 66205/USAFax: +49 (0) 71 57 6 10 00 Fax: +49 (0) 68 35 91 93-29 Fax: +90 3 12 2 95 97 26 www.santa.com.tr info@altmayerbtd.de www.altmayerbtd.de
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