Improve Efficiency and Boost Production

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BULK MATERIAL HANDLING EQUIPMENT

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MAY/JUNE 2023

PUZZLER

When Life Gives

You Lemons...

A guy in a restaurant decides to challenge a waiter. He asks him to bring a glass, plate, water, a match, and a lemon wedge. He then proceeds to pour enough water onto the plate to cover it.

"If you can get the water into the glass from the plate without touching or moving it, you'll get $100", he challenges the waiter.

"You can use all of the items here".

Shortly after, the waiter walks away with the cash. What did he do?

See answer here.

CASE STUDY

Cyclonaire Boosts Production And Reduces Spillage at Proctor & Gamble Plant

The Procter & Gamble Co. manufacturing plant in Vallejo, Mexico - a leading producer of dry laundry detergent - is one of the largest detergent manufacturers in the world. Over time, demand grew to where the plant was handling more than 100,000 tons of sodium carbonate, or soda ash, annually.

Problem

Decreased efficiency and productivity
Excessive air consumption
Costly maintenance with the existing railcar unloading system.

The current system couldn't convey the necessary 25 tn/hr to achieve maximum productivity. Instead, just over 11 tn/hr were regularly conveyed – an immeasurable loss of opportunity and cost. The system was the obvious bottleneck – causing an interruption in material flow.

Another problem was caused by Mexico City’s high elevation and low pressure. The plant’s blower packages ran “hot” – requiring excessive electrical and air consumption at considerable cost. Blowers, needed replacement every two years.

Solution

To improve efficiency and convey rates and to decrease air consumption, the P&G plant decided on a high-capacity HC-Series semi-dense phase pneumatic conveying system from Cyclonaire.

The HC-Series conveyor system was matched with Cyclonaire CycloLift™ railcar/truck connectors, Air Shoot™ gravity conveyors, an intermediate-pressure (15 psig) Blower Package, a Pinch Diverter Valve, and Convey Line — all of which were designed for semi-dense phase vacuum loading/pressure conveying and railcar/truck unloading. A local contractor installed the Cyclonaire equipment. The equipment is in constant use at the Vallejo plant.

Summary

The new automatic system performs more than two times faster than the previous system, while reducing operator time each day and eliminating the need for one operator position entirely — a worker who previously oversaw railcar unloading.

What used to take one hour in freight car maneuver time, takes only 10 minutes using Cyclonaire CycloLifts. Cost savings and power and electrical consumption were also realized because the system is fully integrated. P&G estimated that $281,000 annually would be saved by the reduction of energy consumption and decline in maintenance costs and replacement equipment. Additionally, spillage that once contaminated the environment was noticeably reduced.

To read the entire case study, click here.

HC Series Conveyors

Boost Productivity and Efficiency

The HC Series conveyor is a high capacity, side inlet, vacuum loaded, semi-dense phase conveyor with a capacity to 80+ TPH. It is best suited for powdered materials that are abrasive or fluidizable.

Load Cycle

As the load cycle begins, the suction valve opens while the inlet and discharge flap vales are closed. The air pressure generates a vacuum by patented venturi action. As the vacuum increases in the transfer vessel, the inlet valve opens. Pulled by suction of up to 15″ inches of mercury, the material flows from the source into the transfer vessel. The electronic level control regulates filling of the transfer vessel to optimum levels during the load cycle.

Discharge Cycle

When the transfer vessel has been filled to high level, the inlet and suction valves close and the discharge valve opens. The same positive air supply which created the vacuum is used to push the material into the discharge manifold where it is fluidized for semi-dense conveying, minimizing particle degradation, reducing line wear and increasing system efficiency.

Side vents minimize or eliminate pit depth in low head room scenarios. No need for local filters. Standard features include: carbon steel; high-level probe; source aeration; butterfly outlet value; pressure switch on supply air. Portable up to 30 ft3. 15 PSIG convey air; 90-100 PSIG control air at 3-5 SCFM.

Features

Reduced Venturi Wear - Integral dust separation reduces venturi wear
Less Operator Supervision - Automated controls reduce manpower hours
Adaptable to a Wide Variety of Applications - From bulk carrier, IBC and bulk bag unloading to in-plant transfers
Less Abrasive Wear and Particle Degradation - Semi-dense conveyor uses medium pressure blower air to convey abrasive and/or fluidizable powders at intermediate line velocities.
Shorter Heights than Gravity Fill Version - Ideal for satisfying space requirements