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22. Oktober 2005

GEL Verfahrenstechnik

GEL Verfahrenstechnik

Vacuum suction conveying system with separator filter station and FIBC filling device

In many industrial applications, bulk goods or conveyed material must be separated from the process, be transported to other places for further processing, or be dispensed in a dust-free manner to meet the applicable requirements. To perfectly master such jobs, GEL-Verfahrenstechnik have developed a vacuum suction conveying system equipped with a combined separator filter station and FIBC filling device. To allow mobile applica­tion at different places, the system components have been manufactured in a modular design and are available as stationary or mobile systems. 

Module 1 – the vacuum suction conveying station -  is completely mounted onto a base frame and can be moved by a forklift without any problems. The individual module components consist of a fine filter, of a rotary piston blower which is mounted in a sound-absorbing housing and serves as a vacuum generator, of a blow-out equipped with an exhaust silencer, and of a switch cabinet. 

Module 2 – the combined separator filter station with FIBC filling device – consists of the following main components: The receiving and separating component, the pocket filter element with jet cleaning system, the chamber lock with venting system, the FIBC filling station, and the control cabinet with an integrated PLC for a fully automatic system operation. Module 2 is mounted on a heavy sturdy galvanized steel structure which is provided with special telescopic support bases for transport by forklift or crane. This module has been designed to allow perfect flexibility without having to bolt the base plates to the foundation.

Both modules are connected by a flexible vacuum-proof hose with quick connectors. Connection on the raw gas side can also be made by a flexible hose or to an existing pipe line system. The system can be manufactured in a heat-resistant design allowing to handle material temperatures up to 150 °C. Thanks to the mobility of the modules, the plant is suitable to operate various systems thus offering optimal efficiency and cost reduction

Power supply is ensured by extension cables equipped with plu

g connectors to module 1. Module 2 is supplied via pluggable connection lines from module 1. Module 2 can also be operated via supplied bypass cables, e.g. from a truck battery. Compressed air supply is ensured by an existing pressurized air network or by mobile compressed air units supplied on request. 

Short description of a system supplied for the recycling industry 

The separator plant has been designed to separate dust generated in power stations, E filter ash, as well as granulates. It consists of module 1 (i.e. the combined mobile receiving container with pocket filter and FIBC filling device), and of  module 2 (the stationary vacuum station required to generate the necessary suction pressure). The required pressurized air and electric power as well as the suction hoses/pipe lines have been provided by the customer. 

The vacuum station generates the suction pressure required in the pipe line system or separator system. A rotary piston blower serves as a compressor and is driven by a three-phase motor via a V-belt drive. On the suction side, the rotary piston blower is equipped with an upstream safety filter preventing any dust penetration. The blow-out side is provided with a downstream silencer reducing the blow-off noise level and emitting the air into the environment. In addition the unit is entirely accommodated in a sound-absorbing cabin to minimize the noise emitted by the blower. The cabin is cooled by a fan impeller mounted on the blower shaft. The rotary piston blower is equipped with a starting relief which closes automatically after the system has been started up. In case the admissible blower temperature is exceeded, cooling air is supplied by opening auto­matically. Any operating conditions of the vacuum station are monitored and dis­played. 

Within the receiving container, the air flow being laden with bulk material (= raw gas) is diverted in such a way that all the coarse particles are separated. Due to the under­pressure generated by the vacuum station, the raw gas being laden with fine dust then rises up inside the container and flows through the filter pockets from the outside towards the interior. In doing so, the fine dust deposits on the exterior surface of the filter pocket and forms a so-called filter cake which in turn has a positive influence on the filter efficiency. The clean air (= clean gas) flows through the clean air chamber via the connected pipe line and safety filter and then reaches the suction blower emitting it into the atmosphere. The filter pockets are cleaned by short reversed pulses of compressed air generated by the diaphragm valve/jet tube combination arranged on the clean air side. In doing so, the filter pocket is inflated for a very short time, thus removing a part of the filter cake which falls into the separator component. The diaphragm valves are only actuated individually one after the other in a pre-set sequence. The compressed air intervals (= duration of the pulse and pause between the pulses) can be individually adjusted to each special application. The differential pressure between the dust-laden air side and clean air side is monitored by sensors. A fault warning is given as soon as a pre-set value has been reached. In case the differential pressure is not remained under within a pre-set period of time, the vacuum station will stop. 

Optionally cleaning can also be regulated differential pressure-dependent. In doing so, the differential pressure between the dust-laden air zone and the clean air zone is detected. As soon as a pre-set maximum differential pressure has been reached, cleaning is activated. After the separator plant has stopped, the cleaning system will after-run for an adjustable period, ensuring a trouble-free system re-start. 

The chamber lock below the separator element allows to discharge the bulk material into the downstream FIBC while the system is running. The material falls from the storage cone through the upper rotary valve into the chamber lock. The bypass pipe line and rotary valve are open. As soon as the level limit switch mounted in the chamber lock responds, the upper rotary valve closes. Then the rotary valve in the bypass pipe line closes and the rotary vent valve opens and generates a pressure balance inside the chamber lock. Then the lower rotary valve of the chamber lock opens, and the material falls into the FIBC connected below. Clean surge air is then emitted through the ventilation filter cartridge into the atmosphere. 

Some technical features of the system are:

 

Module 1 –  vacuum station
intake volume flow rate:    30,00 m³/min
inlet pressure (abs.):              0.500 bar
outlet pressure (abs.)             1.000 bar
pressure difference                500 mbar
driving power              37 kW

 
Module 2 – separator filter station
type                                     TAS-2/9
diameter                               1400mm
receiving container                 0.5m³
filter surface                          21.6 m²
heat resistant up to               150°C
 
Chamber lock
type                             AKSP-350/700
effective capacity         approx. 50 litres
acutation                           pneumatic
filter element                          115/300 
 

Control and operation
plain text displays           OP3 Siemens
PLC      S7 Siemens

 

 

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