ISERCO produces many big bag emptying and filling big bag stations with pneumatic powder transfer systems.

Context

A client called on ISERCO to renew its big bag emptying equipment.

This client’s previous installation was equipped with pneumatic massage and a different extraction system from a lump breaker. The problem here is that this emptying station was clogging very frequently.

In addition, the big bag pneumatic massage was not effective. It was hardly ever used. The whole pneumatic transfer line to the reactor was not optimal either, as the line often got clogged as well.

The replacement to optimize the client’s emptying facilities was essential.

The constraints of the project

The main constraint of this project is the available place for the new emptying station implantation. The old equipment is narrower than the new one. The station supplied by ISERCO is equipped with a hydraulic massage that has a larger surface area.

In addition, the emptying station is located inside the building which is subject to a dusty environment daily. For this installation, it is necessary to avoid the risk of explosion due to dust or gas released during the transfer of material. Therefore, the equipment is ATEX 21 certified indoors and ATEX 22 certified outdoors with specifications linked to the client’s very precise standards.

Finally, this client is an industrialist in the chemical sector. Its production site is classified as SEVESO, which imposes important constraints in terms of safety measures to avoid the risk of accidents.

The purposed solution

The big bag emptying station supplied by ISERCO is composed of:

  • A framework with monorail.
  • A pneumatic chain hoist and a 1000 kg APAVE certified steel spreader bar.
  • A stainless steel vibrating hopper, equipped with an ATEX 2/22 motor, 4 silents block, with 2 ATEX 22 push buttons (on/off).
  • A stainless steel unlacing box with an ATEX 2/22 safety inductive sensor, a suction port, and a port with stainless steel plug.
  • A flexible sleeve to ensure the vacuum bag is sealed.
  • A 325 x 325 mm lump breaker with 2 horizontal shafts and an ATEX 2/22 rotation detector. This lump breaker can be partially dismantled for cleaning.
  • A hydraulic massage system used by the operator in case of flow difficulties of one of the emptied products.
  • A pneumatic transfer insertion hopper with filter cartridges to prevent contamination and ensure a better seal.

Focus on the insertion hopper and product route

This is a small buffer hopper designed to receive the product at the lump breaker outlet. This allows the pneumatic transfer system to be filled sufficiently so that there is always product in transit inside.

The pneumatic transport is fed continuously.

This hopper is equipped with high, intermediate, and low-level probes. These enable the crushing and big bag emptying operations to be stopped and resumed according to the level of product contained in the hopper. When the high-level probe is reached, the pneumatic transport starts.

The insertion hopper has a 2-way valve. This allows the customer to feed one of the two reactors of his choice. This is done according to the product filling requirements.

The pneumatic transport aspires for a few tens of seconds, stops aspiring and then releases the product. It repeats this process until the quantity of product required by the client is reached.

Finally, the equipment supplied by ISERCO is a turnkey service that included:

  • Dismantling and disposal of old equipment
  • The assembly of the new installation
  • Mechanical connections between the ISERCO station and the client’s process
  • Commissioning and training of operators

Bulk information

  • Type of industry : Chemical
Product 1
  • Product: Alumina microbead
  • Apparent density: 0.35 to 0.5 kg/l
  • Particle size: 1 to 2 mm
  • Temperature: Ambient
  • Humidity: < to 7% (dry)
  • Toxicology: none
Product 2
  • Product: impregnated mixture
  • Apparent density: 0,7 à 0,8 kg/l
  • Particle size: 1 to 2 mm
  • Temperature: Ambient
  • Humidity: < to 10% (dry)
  • Toxicology: Toxic and CMR (Carcinogenic, Mutagenic and Reprotoxic)