Category Archives: News from Industry

ACS puts your valves through some (really) rigorous tests

Each component of a pneumatic conveying system is necessary to keep your products flowing, and your employees safe on the plant floor.

We like to think of our valve tests in the same way—each separate step of the test is important to keep our valves working their best, and keep safety a priority.

ACS_Valves_pix

This is why we have a 46-step inspection on each of our valves.

We have our specialists sign off on each step before the different components of our valves can go further in their manufacturing process.

Each separate part of our rotary valves are inspected at different stages including:

  • Endplates
  • Bearings
  • Rotor assembly
  • Housing
  • Drive guard assembly
  • Drive mounting base
  • Drive package
  • Sprockets and chain
  • Speed switch assembly
  • Final valve assembly
  • Paint

The valves are also tested for several components at each stage. Some of these include:

  • Casting construction
  • Condition of casting before and after machining
  • Correct sizing and tolerance on various parts
  • Chrome plating
  • Cosmetic appearance
  • Clearances
  • Quality of welding

It’s important for us to have NFPA and OSHA-compliant valves as a part of our standardized safety, which is why we include real-life testing in a factory floor setting. We make sure our valves include the options needed for your specific application and optimum performance.

Ours last for ten minutes to make certain not only the valve is running properly, but that the electrical components are as well. We check that the gearmotor is working properly and running at proper amperage. We also record the amperage readings during this time.

Our live tests are also when we make sure that the valve is rotating properly, and running as they should be. For your convenience, our inspectors record both rotor tip and side clearances on the top inlet flange, and on inspection sheets for proper record keeping.

Finally, our valves are inspected at the shipping stage to make sure all of the data from our 46-point inspection corresponds to the bill of materials. Shipping quality is also signed off at this time.

Our quality control manager, Bob Timson, completes a rigorous quality check before each of our valves is shipped out.

All inspection documentation is available upon request. If you need assistance please do not hesitate to contact us for technical support.

 

Megan Thompson, ACS President & COO
Megan Thompson, ACS President & COO

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Munson Machinery: Ribbon Blender Meets Sanitary Standards

Utica, NY, USA  –  A new Munson Ribbon Blender that meets sanitary standards, blends up to 1.84 m3 of powders, pastes or slurries. The unit, model HD-3.5-7-S316, is constructed of #316 stainless steel with continuous welds having 6 mm radii polished to 150 grit, a #4 (-32 Ra) interior surface finish and external removable seals.

The blender’s 2:1 length-to-diameter ratio is said to distribute ingredients uniformly during loading, blending and discharge.

It forces a split double-helical agitator through stationary material, producing homogeneous blends in 5 to 6 minutes typical. Tight tolerances of 1.6 to 0.8 mm between ribbon blades and the vessel wall minimise residual product in the trough following discharge, reducing material waste and cleaning time.

It is equipped as standard with a hinged and gasketed cover with safety interlocks, and available to Pharmaceutical and USDA Dairy standards with continuous welds finished up to 240 grit and #6 or electropolished interior surface finishes.

Other options include a dust hood inlet with removable grating for ease of loading, spray lines for liquid additions, multiple discharges, special drive arrangements and CIP manifolds.

Available sizes range in capacity from .03 to 28 m3.

Other Munson mixing and blending equipment available to sanitary standards includes Paddle Blenders, Cylindrical Plow Blenders and Rotary Batch Mixers. Size reduction equipment available to sanitary standards includes Pin Mills, Screen Classifying Cutters, High Intensity Mixers and Rotary Lump Breakers.

Constructed to sanitary standards, Munson's Ribbon Blender model HD-3.5-7-S316, allows rapid sanitising between batches, preventing cross contamination.
Constructed to sanitary standards, Munson’s Ribbon Blender model HD-3.5-7-S316, allows rapid sanitising between batches, preventing cross contamination.

 

AIMS: Aachen International Mining Symposia (AIMS 2016) – MINING IN EUROPE

AIMS:

Aachen International Mining Symposia (AIMS 2016)

MINING IN EUROPE

18 – 19 May 2016
Aachen, Germany

AIMS 2016 | EARLY BIRD – REGISTRATION AVAILABLE NOW! | CALL FOR PAPERS!

 

The Institute of Mineral Resources Engineering (MRE) of RWTH Aachen University in Germany is pleased to announce that the online registration is now available at http://www.aims.rwth-aachen.de/registration/.

Continue reading AIMS: Aachen International Mining Symposia (AIMS 2016) – MINING IN EUROPE

WAMGROUP- Drymix Production in Indonesia

For their dry building materials processing plant in Cikarang Utara, Bekasi, West Java, Indonesia, a renowned global player chose WAMGROUP® equipment.

Continue reading WAMGROUP- Drymix Production in Indonesia

4B`s New SpeedMaster – Speed Switch Sensor & System Testing Device

NEW SpeedMaster – Speed Switch Sensor and System Testing Device

Leeds, UK 4B Braime Components Ltd. is pleased to announce and introduce our next generation SpeedMaster™ diagnostic tool.

The SpeedMaster™ with Pulse Pilot is the only device that provides independent, real time, and complete verification of an entire speed monitoring system to ensure that alarms and shutdowns are working as expected.

Continue reading 4B`s New SpeedMaster – Speed Switch Sensor & System Testing Device

Martin Engineering: Air Cannons Mitigate Chute Plugging at Texas Cement Plant

New Braunfels, Texas –  A global innovator of bulk material handling technologies has used high-performance air cannons to help a cement plant prevent material backup due to a clogging transfer chute. With a total production of 2.3 million tons annually, the Hunter Cement Plant in New Braunfels, Texas — owned and operated by Martin Marietta — experiences heavy rain dousing raw material on its partially covered, tower-mounted D-07 conveyor system. Wet dust and aggregate would clog the chute and cause backups on the belt, leading to spillage issues that halted production and took 6-8 hours to clear. The solution employs a series of Martin® Hurricane Air Cannons strategically placed along the chute to improve material flow, minimize unscheduled downtime and reduce clean-up.

Limestone extracted from the Hunter quarry is crushed to a size of 6-inch minus (150mm) and mixed with clay, then conveyed to a processing tower. Separate conveyors deliver iron ore and sand to the same tower and the two chutes offload 350 to 400 tons (317.5 to 362.8 metric tons) per hour onto the D-07 conveyor, mixing them together on the 42 in. (1068 mm) single belt running at 350 FPM (1.8 MPS).

Two chutes offload up to 400 tons (362.8 metric tons) per hour onto the D-07 conveyor.
Two chutes offload up to 400 tons (362.8 metric tons)
per hour onto the D-07 conveyor.

The conveyor travels approximately 300 feet (91.4 m) to an adjacent tower and offloads into a pyramid-shaped funnel, which feeds a chute 12 foot-long (3.65 m), 3 ft. by 3 ft. (.91 m) square chute with a flow control gate at the bottom. The gate either diverts material to a conveyor leading to the raw mill or to a dump truck waiting on the ground below. Operators found that wet or damp material gradually formed into a rat hole and eventually created an obstruction, which led to the material back-up.

When the material flow began to choke off, two or three workers would gather around the railing at the top of the chute and use air lances and pneumatic jackhammers fitted with 8-foot long bits to clear the obstruction.

According to a management source, “The frequent unscheduled downtime to clear the rotary feeder chute was a challenge. We approached Martin Engineering to explore the possibility of adding air cannons that could help resolve the bottleneck issue.”

Air Cannon Placement for Proper Flow

Martin technicians installed a total of five 70-liter air cannons on two levels. The 94 lb. (43 kg) tanks are suspended from the tower frame by steel cords and are fed by the plant’s existing compressed air system. They fire a shot of air at up to 120 PSI (8.27 BAR) from a pressurized tank through a fan jet nozzle with a 12-inch (305 mm) wide mouth, which spreads the stream across the surface area of the wall. To clear obstructions and assure proper material flow, the cannon has an effective area of up to 22.6 ft3 (640 L).

Martin technicians installed five 70-liter air cannons on two levels, suspended by steel cords.
Martin technicians installed five 70-liter air cannons
on two levels, suspended by steel cords.

On the upper level, two of the cannons were placed along either side of the chute to dislodge accumulation from the wall, and a third unit was installed at the top to free any material that could get trapped where the chute narrows. One floor below, a cannon is directed at a downward angle to aid material flow, whereas the lowest unit on the chute specifically addresses the easily clogged diverter gate.

All fitted with a centrally located valve design, the tanks offer a direct air path with maximum force output and low air consumption. This efficiency reduces the burden on the compressor and shortens the lag time between sequences. The central valve is a detachable component that allows a single worker to disconnect it without the need to remove the tank, for faster and easier maintenance.

The central valve design delivers a direct air path, with maximum force output and low air consumption.
The central valve design delivers a direct air path,
with maximum force output and low air consumption.

A 10-bank positive solenoid control panel is connected to the facility’s programmable logic control (PLC) software, allowing operators to control and monitor the proper firing time and sequence from a remote location. To eliminate the risk of unintentional firing due to drops in pressure, the valve requires a positive signal from the solenoid in the form of an air pulse to trigger discharge.

Result

A few months after the installation, operators report that the air cannon solution has significantly decreased the plugging issues, resulting in continuous operation with minimal unscheduled downtime. Moreover, the area around the chute is reported to need only routine cleanup and maintenance accompanying normal scheduled inspections.

“Due to our long and positive relationship, we were confident that the Martin Engineering team was going to come through,” Martin Marietta management concluded. “The equipment has worked out well, and with the team’s consistently attentive service, we are confident that this is a good solution.”

Along with hundreds of air cannons, Martin Engineering has also equipped the Hunter Cement plant with conveyor accessories and bulk handling solutions. Founded in 1944 and headquartered in Neponset, IL — with divisions on 6 continents — the equipment designer and manufacturer is a world leader in flow aids and conveyor products for a wide variety of bulk material applications, including cement, coal, rock / aggregate, biomass, grain, pharmaceuticals, food and other materials. For more information, visit or call (309) 852-2384.

Important Product Selection Links:

Flow Aid Solutions

Air Cannons

Air Cannon Accessories

Sonic Horns

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WAMGROUP in Brazil

Discovering WAM® in Brazil

São José dos Campos, São Paulo, Brazil, December 2015

Since 1999 WAMGROUP® has been represented in Brazil by its own subsidiary near São Paulo, the country’s economic and financial capital.

Responsible for distribution of the WAMGROUP® product range in Brazil and, since 2001, as the Group’s South American manufacturing hub for screw conveyors and other WAMGROUP® equipment, it is the goal of WAM do Brasil to provide a vast customer base with attractively priced products in industrial quality, specifically tailored to the different needs of a variety of industries in their home market and in some neighbouring territories. Customer satisfaction through professional advice, comprehensive service and constant availability backed up by a vast stock of equipment, accessories and spare parts are an expectation WAM do Brasil is ready to fulfil day by day.

By starting production at WAM do Brasil in 2001, WAMGROUP® confirmed its intention of a long-term presence in the South American marketplace.

While according to WAM do Brasil’s general manager, Andrea Ferri, the short-term outlook on the Brazilian economy is not positive, the country’s high potential in terms of natural and professional resources is leaving WAMGROUP® confident about future business opportunities.

BA Bin Activator by WAMGROUP
BA Bin Activator by WAMGROUP

 

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BEUMER Group: New Business Segment AFR Systems

The new business segment AFR systems at BEUMER Group makes it possible for cement and lime plants to use alternative fuels:

Reliable energy supplier

Cement manufacturing is particularly energy-intensive. In order to reduce the use of expensive primary fuels like coal and oil, cement plant operators focus increasingly on alternative fuels and raw materials (AFR). The use is generally focused on the fuels. Neither the manufacturing process, the end product, nor the emissions may be affected. Therefore, high-caloric wastes that cannot be further recycled, e.g. from plastic and packaging residues, paper, composite material or textiles, have to be treated beforehand to be ready for incineration.

In order to help customers efficiently convey, store and dose the treated fuels, BEUMER Group has established the new business segment AFR systems.

Germany, October 1973: For political reasons, Arab countries reduced their oil production, which caused oil prices to skyrocket. This was a very precarious situation, because crude oil was an important energy source, also for the cement industry to operate their rotary kilns. With this first oil crisis, plant operators started to shift towards using cost-effective fuels and raw materials.

Besides mineral waste that can be used as alternative raw material, the market primarily employs the use of fuel alternatives, because approximately 30 per cent of production costs are spent on energy. In addition to fluid alternative fuels, such as used oil or solvents, the majority of solid fuels consist of complete or shredded scrap tyres, scrap wood, or mixtures of plastic, paper, composite materials or textiles. After they have been treated and quality-controlled, they show calorific values similar to brown coal. The calorific value of scrap tyres is even comparable to that of stone coal. When producing cement, it is also necessary to ensure that the quality of the ash residues matches the quality of the end product. As all material components are completely incorporated into the clinker and mineralised. Their use makes for an economic production process. In addition, primary raw and fuel supplies are conserved and landfill volume is reduced.

Fig. 1: The alternative fuels are conveyed from the storage to the main burner, low in noise and dust-proof.
Fig. 1:
The alternative fuels are conveyed from the storage to the main burner, low in noise and dust-proof.

Pre-treated secondary fuels are mostly supplied from external vendors, ready for incineration. BEUMER Group now offers tailor-made AFR systems to lime and cement plants for the safe transport and storage of solid materials. Based on wide-ranging experiences and the customer’s requirements, the systems comprise the entire chain, from receiving and unloading the delivery vehicle, up to storing, sampling, conveying and dosing solid alternative fuels. BEUMER Group, provider of intralogistics, supplies its customers worldwide now with three systems, from one single source.

Tailored to every application

BEUMER Group‘s program includes the starter system that is used at the main burner. In the cement and limestone industry, primary fuels are usually ground to grain sizes of less than 100 micrometres and fed via the burner. At the end of the rotary kiln, the burner heats up to 2000 °C, the temperature that is needed for limestone, sand, clay and ore to react and become clinker as an intermediate product. In order to use solid secondary fuels in the clinkering zone burner, they should deliver a calorific value that is at least similar to brown coal (ca. 22 ± 2 MJ/kg), have grain sizes of less than 30 millimetres and burn out while being fed.

The oven-ready material is usually delivered in moving-floor trailers. BEUMER Group provides a docking station that also serves as storage on site. Once the trailer is emptied, it is completely replaced or refilled in the large tent using a wheel loader. The material is metered volumetrically and conveyed to the clinkering zone burner. This solution is deliberately designed as a test system. This way, the operator can test their suppliers, the quality of the fuels and their furnace behaviour.

Fig. 2: By using alternative fuels, the production process becomes more economical. Primary raw materials and fuels are conserved and landfill volume reduced.
Fig. 2:
By using alternative fuels, the production process becomes more economical. Primary raw materials and fuels are conserved and landfill volume reduced.

 

Solution for the calciner

With the second system, the calciner can be fed with more coarse alternative fuels, such as tyre derived fuel or the fuels described above, but in a more coarse state. They are generally less processed, contain three-dimensional particles and therefore require more time to burn out than for example the more intensively processed, exclusively two-dimensional secondary fuels for the main burner.

The coarse calciner fuel is delivered in moving-floor trailers or tippers. The secondary fuels are quickly unloaded and stored temporarily in a dust-proof way. Another storage serves as a flow buffer, which can hold the overall capacity of 900 cubic metres of the preceding bunker. From here, the Pipe Conveyor transports the material to the calciner in the preheater tower. Here, the secondary fuel is weighed and dosed. During the feed towards the hearth in the calciner, there is often the risk that the material or the conveying system can catch fire due to thermal radiation or pulsations. For this reason, the valveless special feed was developed, so the material can be safely fed to the calciner.

In order to ensure safe and automatic fuel supply after successful testing, BEUMER Group provides systems for permanent operation with high thermal substitution rates. The systems consist of the receiving area and a storage system, where the crane system can store material of different quality into different storage zones and boxes. Experiences so far have shown that you always have to calculate with disruptives or quality deficits in the fuel. This is why the entire storage and conveying technology in the hall can be provided with equipment that is able to separate metal, wet and three-dimensional disruptives from the fuel for the main burner and keep disrupting oversized grains from the calciner fuel.

Equipped with the necessary sensor technology, the operation runs automatically. The crane can be used independently for homogenisation, in order to minimise quality variations or feed the lines towards the main burner and the calciner.

Fig. 3: Fill level measuring probes and other measuring technology monitor the automated processes.
Fig. 3:
Fill level measuring probes and other measuring technology monitor the automated processes.

Pipe Conveyor stands the test

Schwenk Zement AG‘s product diversity and production capacity make their plant in Bernburg one of the largest and most efficient cement plants in Germany.

In order to reduce energy costs, the cement plant is increasingly using secondary fuels that are engineered in external processing plants into high-quality fuels with defined product parameters.

Until now, the manufacturer had been using drag chain conveyors. After almost a decade of use and numerous modifications however, more and more maintenance was required. The fuel quality also improved over time, so that, due to its density of 0.2 t/m3, the existing technology was no longer sufficient to convey the required quantities towards the main burner. This created the need for a reliable, eco-friendly and low-maintenance solution. In addition, the new conveyor needed to be optimally adapted to the curved routing in the plant.

Fig. 4: If suppliers encounter problems in regards to the quality of their processing, BEUMER AFR systems can be upgraded and are suitable for high substitution rates. Photos: BEUMER Group GmbH & Co. KG
Fig. 4:
If suppliers encounter problems in regards to the quality of their processing, BEUMER AFR systems can be upgraded and are suitable for high substitution rates.
Photos: BEUMER Group GmbH & Co. KG

Schwenk Zement KG opted for the BEUMER AFR system with its Pipe Conveyor to feed the main burner with alternative fuels. The system works almost completely automatically, from receiving to the feeding system of the rotary kiln. Cranes pick up the engineered secondary fuels in the storehouse and fill them into the discharge bunkers with their discharge equipment. From there, a chain belt conveyor transports the fuel continuously towards the Pipe Conveyor, which conveys it to the weigh feeders before the main burner.

The curved Pipe Conveyor at the core of the system requires little maintenance and its enclosed design and quiet operation protect against emissions and the wind-blown dispersal of the fuel. It is able to connect long distances without interruption and navigate tight curve radii that adapt to the individual conditions of the plant.

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The BEUMER Group is an international leader in the manufacture of intralogistics systems for conveying, loading, palletising, packaging, sortation and distribution. Together with Crisplant a/s and Enexco Teknologies India Limited, the BEUMER Group employs 4,000 people worldwide, and achieves an annual turnover of about 680 million EUR. With its subsidiaries and sales agencies, the BEUMER Group serves customers around the globe, across a wide range of industries.

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Magaldi Calls for Support to Become the National “Public” Champion for Italy

Magaldi has already been named as one of the National Champions in this year’s European Business Awards but the challenge has not come to the end yet: we are currently competing against all other country National Champions for the public vote!

We realized a short video in order to give a powerful insight into the story of our business and success and to share our values based on the development of innovative and dependable solutions aimed at the Customer satisfaction, the respect of the most severe environmental regulations and the total safety for operators.

The video has been published on the EBA website and it’s available at http://www.businessawardseurope.com/vote/detail-new/the-business-of-the-year-award-with-turnover-of-26-150/16944. You’ll be able to vote until 26th February 2016.

The company receiving the most votes will be named ‘National Public Champion’ for Italy on 7th March 2016.

 

Paolo Magaldi, Member of the Board, Magaldi Industrie S.r.l.
Paolo Magaldi, Member of the Board, Magaldi Industrie S.r.l.

Please click here for Magaldi Video.

We are hoping that the public will watch our video and vote for us since the public vote means a great deal as it is both our existing and potential Customers and Clients giving their approval to our success.

So we ask you to take some time, watch our video, and cast your vote!

 

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