Silo-Flow™¢ and Turbo-Flow™¢ are new technologies that successfully eliminate the toughest bulk materials flow problems in regular and in kiln applications.
Bulk solids, when handled in-plant, require to be temporarily stored before it can be sent to the next stage of processing. Due to the inherent characteristic of the material or the moisture in it, the flow gets impeded, which ultimately effects the production in the plant. This phenomenon has always been a nightmare for the plant operator. A new technology has been developed which sends high pressure pneumatic shock waves into the material build-up, causing its disintegration. This technological break-through has been best described through the following case study.
The silo-flow™¢ technology
The Silo-Flow™¢ patented technology was developed and designed to solve the toughest bulk material storage and process flow problems. The Silo-Flow™¢ system can be installed on all types of feeders, hoppers, bins and silos. A souped-up version of this technology, known as Turbo-Flow™¢adds water bursts to the high pressure air pulses and is used for cleaning high-temperature facilities such as kiln pre-heaters and calciners.
The Silo-Flow Device & Turbo-Flow Device are made of high grade stainless steel and designed for very high pressures. Unlike standard air cannons that use up to 100 psi (7 bar) provided by the plant air pressure line, Silo-Flow™¢ and Turbo-Flow™¢ use compressed air at up to 3000 psi (200 bar), supplied by a dedicated high-pressure compressor through a couple of buffer air cylinders. The device creates a powerful shock wave followed by a high velocity air stream. The shock wave and air stream are generated inside the vessel and dislodge any build- up inside;the sheer force of the device combined with its quick repeat action, leaves no material stuck to the vessel walls. As a result, the Silo-Flow™¢ system maintains a continuous material flow, even with the most problematic materials or structure designs.
The device can be activated from the control room or by a stand-alone timer. The SFD is then programmed to fire at pre-determined intervals depending on the application. Typical air cannons fire once every few minutes depending on their tank’s filling rate. Silo-Flow™¢ can fires every few seconds as long as the air supply is kept on. In addition, the air pressure can be fully controlled from as low as 300 psi (20 bar) to 3000 psi (200 bar). This provides operators maximum flexibility to ensure that even the toughest material does not settle, and adapts the system to varying material and weather conditions.
The SFD requires minimum maintenance including an annual check and a seal replacement, a piston replacement every three to five years and an occasional attendance to the compressor (adding oil, cleaning the filter, etc).
Several cement manufacturers have installed or are planning to install Flow Industries’ latest product the Turbo-Flow™¢ on their pre-heater towers. The Turbo-Flow™¢ system uses the Turbo-Flow Device and adds bursts of water the high pressure air stream. This patent-pending technology creates a high pressure spray that spreads over the entire pre-heater wall and wipes out any build-up. A dedicated shock-absorbing system protects the wall’s internal refractory lining. Today, dozens, sometimes hundreds of air cannons, are installed at the pre-heaters towers or coolers and often, they become a maintenance nightmare. Moreover, air cannons have a limited range and do not solve build-up problems. Most operators have to rely on frequent manual cleaning by the water jets. Contrary, one Turbo-Flow™¢ unit typically covers an entire 3x3m pre-heater wall and keeps it clean. By using Turbo-Flow™¢ cement manufacturers can simplify their pre-heater maintenance, reduce costs by moving to lower grade fuels, reduce and even eliminate manual cleaning, a dangerous and unpleasant job.
Turbo-Flow™¢ unit installed on the corner of the riser-duct. Note the air and water supplies. Riser-duct internal wall kept completely clean after the Turbo-Flow™¢ is installed on the adjacent wall. You can find Silo-Flow™¢ and Turbo-Flow™¢ systems around the globe, used by all the leading cement manufacturers like Lafarge, Italcementi, Cemex, HeidlebergCement, Holcim and many others.
For more information please contact:Tega Industries Limited, 13,Zamir Lane,Near Ballygunge Rly. Station, Kolkata 700 019, Tel: +91 33 3370 0400 Or email to: info@tegaindustries.com
(Communication by the management of the company)