tag:blogger.com,1999:blog-15659451512799228342024-02-19T02:44:44.384-08:00Process Systems & Design BlogProviding information on bulk materials handling (liquid and solid), plant systems engineering, specialty machine design, and process control engineering. Industry focus for the following posts are bulk handling systems, E-Liquid (E-Juice) manufacturing equipment, Biomass, plastics and polymers. For more information, visit <a href="http://processsystemsdesign.com">PS&D</a> or call (410) 861-6437Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comBlogger33125tag:blogger.com,1999:blog-1565945151279922834.post-11336826512910236432018-01-19T09:08:00.003-08:002018-01-19T09:08:46.879-08:00What is FRP?<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWlOB7rIrwEzUH5gbzLZExeZfbDiA98FlmiwTtqyEs5N7ac6lYvCf6WELKq1igWXhkHEwqlWeOcczICV-1c9hqRjvk_Y3tpQE__lgaAm2zbdPimYtuCInbQqsltcjEQnbIZevCn5VtcAU/s1600/FRP-1-Process-Systems-Design.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="Fiber Reinforced Polymer" border="0" data-original-height="340" data-original-width="453" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWlOB7rIrwEzUH5gbzLZExeZfbDiA98FlmiwTtqyEs5N7ac6lYvCf6WELKq1igWXhkHEwqlWeOcczICV-1c9hqRjvk_Y3tpQE__lgaAm2zbdPimYtuCInbQqsltcjEQnbIZevCn5VtcAU/s320/FRP-1-Process-Systems-Design.jpg" title="Fiber Reinforced Polymer" width="320" /></a></div>
A basic definition of Fiber Reinforced Polymer (FRP) is a composite material comprised of fiber (aramid, carbon, or glass – being the most common) and polymer resin commonly referred to as epoxy. FRP is a generic term for Aramid Fiber-Reinforced Polymer (AFRP), Carbon FiberReinforced Polymer (CFRP), and Glass Fiber-Reinforced Polymer (GFRP). FRP used for strengthening civil structures traces its roots to the mid-1980s with the first installations occurring in Europe and Japan. Today, thousands of rehabilitation projects around the globe have employed these composites to add strength to concrete, masonry, timber, and steel structures.<br />
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The motivation to develop FRP for civil structures was to provide an alternate to conventional strengthening methods. Some of the conventional methods include steel plates epoxy-bonded to concrete, steel plates bolted to concrete, and steel plate jacketing of round, square, and rectangular concrete columns. The obvious disadvantage of conventional methods is that they are heavy and difficult to install. In addition, once steel yields, it will stretch with little strength gain. However, FRP is linear-elastic to failure. It has roughly the same tensile modulus as steel; thereby, making it a nice alternative to steel.<br />
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Contact <a href="https://www.processsystemsdesign.com/" target="_blank">Process Systems & Design</a> to discuss more about the use FRP in industrial process design and construction. Visit <a href="https://www.processsystemsdesign.com/">https://www.processsystemsdesign.com</a> or call (410) 861-6437.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-55394247162072879392018-01-09T10:00:00.000-08:002018-01-09T10:02:55.192-08:00Composite Materials for Industrial Construction and Process Equipment<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3V5MJyfv_KloTdN74581p996Eqo0uRd_p_lL43ZuvHCrnBpa0FsAWZVVUny0dPzkFg71xv1g99vX54v537zo9OyqZdZ9MDaGbVeY0VkqblSL0QfORn3rbhnOCfSygaSqZuSWPh3R8ggs/s1600/Composit-Material-in-Process-Contruction.jpg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Composite Materials for Industrial Construction" border="0" data-original-height="700" data-original-width="734" height="305" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3V5MJyfv_KloTdN74581p996Eqo0uRd_p_lL43ZuvHCrnBpa0FsAWZVVUny0dPzkFg71xv1g99vX54v537zo9OyqZdZ9MDaGbVeY0VkqblSL0QfORn3rbhnOCfSygaSqZuSWPh3R8ggs/s320/Composit-Material-in-Process-Contruction.jpg" title="Composite Materials for Industrial Construction" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Composite Materials for Industrial Construction.</td></tr>
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A composite can be defined as a combination of two or more materials that retain their macro-structure resulting in a material that can be designed to have improved properties than the constituents alone. Fiber-reinforced polymer (FRP) composites are made by combining a polymer resin with strong, reinforcing fibers.<br />
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Typically, a composite material is made of reinforcement and a matrix. The reinforcement material provides the mechanical strength and transfers loads in the composite. The matrix binds and maintains the alignment or spacing of the reinforcement material and protects the reinforcement from abrasion or the environment. The combination of a matrix material with a strong reinforcement material enables lighter weight products relative to monolithic materials (like metals) with similar or better performance properties. Resin and fibers can be combined in a multitude of ways and further processed through a series of forming and consolidation steps. The specific manufacturing technique is dependent on the resin material, the shape and size of the component, and the structural properties required by the end use application.<br />
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The landscape of manufacturing segments and systems that benefit benefit from the lower cost, high strength and stiffness, corrosion resistant, and lightweight composite materials is growing. Successful industrial implementations for composites include material handling systems, compressed gas storage systems, heat exchangers, pipelines, geothermal energy equipment, turbine blades, structural materials for buildings, power generation flywheels, support structures for solar systems, and shipping containers, just to name a few.<br />
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For more information on applying <a href="https://processsystemsdesign.com/article_87_Pultruded-FRP-Composites.cfm" target="_blank">composite materials for industrial construction or process equipment</a>, contact <a href="https://processsystemsdesign.com/" target="_blank">Process Systems & Design</a> at (410) 861-6437 or visit <a href="https://www.processsystemsdesign.com/">https://www.processsystemsdesign.com</a>.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-68310897938981554672017-12-30T06:47:00.004-08:002017-12-30T06:47:43.290-08:00Happy New Year from Process Systems & DesignWith 2017 coming to a close, all of us at <a href="https://processsystemsdesign.com/" target="_blank">Process Systems & Design</a> wanted to reach out and send our best wishes to our customers, our vendors, and our friends! We hope that 2018 holds success and good fortune for all of you.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmZo3QhbhlqNMpi6MOrO2mbH_rMF3KscRe8xi7-2PITU0iBMN3NUu9eVMOnVzmwNr83yjlghjdRVb2rBsw8os1Zbpf4mcrYFkmZswS7n17pL_pmH2Vqql2o50_6GhuLd2tM2c-buDoUWo/s1600/2018-PSD.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="850" data-original-width="1280" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmZo3QhbhlqNMpi6MOrO2mbH_rMF3KscRe8xi7-2PITU0iBMN3NUu9eVMOnVzmwNr83yjlghjdRVb2rBsw8os1Zbpf4mcrYFkmZswS7n17pL_pmH2Vqql2o50_6GhuLd2tM2c-buDoUWo/s400/2018-PSD.jpg" width="400" /></a></div>
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-32928396843359067502017-12-28T04:57:00.000-08:002017-12-28T05:23:54.550-08:00Sludge Removal by Wastewater Treatment ClarifiersAs the video below points out, dirty wastewater enters from the center of the clarifier and very slowly makes its way towards the outside where the water spills over the weir. During that retention period, the solids have enough time to settle to the bottom, where they're later picked up as sludge, and the clarified, or cleaner water, spills out along the edge. Clarifiers are made in many different shapes and sizes all work on basically the same principle. The sludge is then processed to remove water, be neutralized biologically, and reduce the levels of pathogenic organisms.<br />
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Beneficial uses of treated municipal wastewater sludges on land include agriculture and silviculture uses; application to parks, golf courses, and public lands; use in reclaiming low quality or spoiled lands; and use as landfill cover or fill material. Disposal on land includes landfilling and permanent storage of dewatered sludge or sludge incinerator ash in lagoons or piles.<br />
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<iframe allow="encrypted-media" allowfullscreen="" frameborder="0" gesture="media" height="315" src="https://www.youtube.com/embed/IUTJhEZAKCM?rel=0&showinfo=0" width="560"></iframe></div>
Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-25774104642650092912017-12-19T05:56:00.000-08:002017-12-19T05:57:19.430-08:00Pultruded FRP Composites as an Alternate to Steel<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjglOXnAVLpnzGjBOnG6dQ8_Zs2JrwOEP8nJ2tt3mN58zks2U262rXgqudHka1L20BADytSupPy4vxBpEYaYLnGK3POuTJdfAyNFBBhNzrW-K3-mDPHKJ-WwzHkExNE5Z5CqGW0dsQMS7g/s1600/Pultruded-FRP-Composites-Process-Systems-Design.png" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Pultruded FRP suspendible roof structure" border="0" data-original-height="488" data-original-width="599" height="260" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjglOXnAVLpnzGjBOnG6dQ8_Zs2JrwOEP8nJ2tt3mN58zks2U262rXgqudHka1L20BADytSupPy4vxBpEYaYLnGK3POuTJdfAyNFBBhNzrW-K3-mDPHKJ-WwzHkExNE5Z5CqGW0dsQMS7g/s320/Pultruded-FRP-Composites-Process-Systems-Design.png" title="Pultruded FRP suspendible roof structure" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Pultruded FRP suspendible roof structure.</td></tr>
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Pultrusion is a term that describes a manufacturing process for producing continuous lengths of FRP (fiberglass reinforced plastic) where reinforcing fibers are saturated with resin and pulled through a heated die to form a part. The result is a straight, constant cross-section profiles similar to standard steel shapes.<br />
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Pultruded composite sections can be used to design and install lightweight, corrosion-resistant and electrically non-conductive alternatives to steel structures, particularly where speed and ease of construction are important. Pultruded FRP has performance characteristics similar to other construction metals, but unlike steel, it is EM/RF transparent and doesn’t disrupt equipment signals.<br />
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<b>Benefits:</b><br />
<ul>
<li>Pound-for-pound stronger than steel.</li>
<li>Comparable structural performance to other metals such as aluminum, but without the conductivity, corrosion or impact limitations. </li>
<li>Can be painted, coated or pigmented during manufacture for little-to-no maintenance in highly aggressive environments</li>
<li>Designed for UV performance</li>
<li>Enables rapid cleaning with aggressive solvents at high pressures</li>
<li>Meets industry requirements for durability, smoothness, absorbency, color, corrosion resistance and washability</li>
</ul>
<b>Typical Uses:</b><br />
<ul>
<li>Structural profiles and plates</li>
<li>Decking and planking</li>
<li>Platforms, stairs, ladders and cages</li>
<li>Handrails, guarding and kickplates</li>
<li>Grating and gridmesh</li>
<li>Bridge components</li>
<li>Structural building panels</li>
<li>Sheet piling and round pile</li>
<li>Containment systems</li>
<li>Ballistic and storm panels</li>
<li>Connection hardware</li>
</ul>
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Pultruded FRP composites are ideal for structural elements where a strong, lightweight material is needed; corrosion is a concern for steel or other metals; RF permeability is needed; and low thermal or electrical conductivity is important.</div>
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To discuss using pultruded FRP composites on your next project, contact <a href="https://www.processsystemsdesign.com/" target="_blank">Process Systems Design</a> by calling (410) 861-6437 or visit <a href="https://www.processsystemsdesign.com/">https://www.processsystemsdesign.com</a>.</div>
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-14210320402255907082017-12-10T11:04:00.002-08:002017-12-10T11:07:18.053-08:00Consider the Possibility of Constituent By-products in Your Process Heating System<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju0aUgv5GQcbjH6n9K3wEZjIE5QYNTudUZIiT5kclSbXx46YBsX84b9SakvPdhGaMZ4sxFO2e0scStn-GhohoX1hP_YYDxnT6OgKWTxnrBKitpJOUMFUUpKYvsAlqx-h0QZ57saoUU25Y/s1600/Process-Heating.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="Process Heating System" border="0" data-original-height="362" data-original-width="300" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju0aUgv5GQcbjH6n9K3wEZjIE5QYNTudUZIiT5kclSbXx46YBsX84b9SakvPdhGaMZ4sxFO2e0scStn-GhohoX1hP_YYDxnT6OgKWTxnrBKitpJOUMFUUpKYvsAlqx-h0QZ57saoUU25Y/s320/Process-Heating.jpg" title="Process Heating System" width="265" /></a></div>
It is estimated that over 7,000 TBtu/year (Trillion British Thermal Units) of energy is used for process heating by the manufacturing sector in the United States. This energy is in the form of fuels—mostly natural gas with some coal or other fuels—and steam generated using fuels such as natural gas, coal, by-product fuels, and some others.<br />
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Combustion of these fuels results in the release of heat, which is used for process heating, and in the generation of combustion products that are discharged from the heating system. All major US industries use heating equipment such as furnaces, ovens, heaters, kilns, and dryers. The hot exhaust gases from this equipment, after providing the necessary process heat, are discharged into the atmosphere through stacks. The temperature of the exhaust gases discharged into the atmosphere from heating equipment depends on the process temperature and whether a waste heat recovery (WHR) system is used to reduce the exhaust gas temperature. The temperature of discharged gases varies from as low as 200°F to as high as 3000°F.<br />
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Combustion products themselves, generated from well-designed and well-operated burners using gaseous and light liquid fuels, are relatively clean and do not contain particles or condensable components that may require “cleanup” before discharge into the atmosphere. <b>However, during the heating process, the combustion products may react or mix with the product being heated and may pick up constituents such as reactive gases, liquid vapors, volatiles from low-melting-temperature solid materials, particulates, condensable materials, and the like.</b><br />
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Some or all of these constituents, particularly at high temperatures, may react with materials used in the construction of downstream heat WHR equipment and create significant problems.<br />
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<b>Potential Problems:</b><br />
<ul>
<li>Chemical reaction of exhaust gases and their solid or vapor content with the materials used in the WHR equipment.</li>
<li>Deposit of particulates in or on surfaces of WHR equipment.</li>
<li>Condensation of organics such as tars and inorganic vapors such as zinc oxides and boron on heat exchanger surfaces.</li>
<li>Erosion of heat exchanger components by the solids in the exhaust gases. </li>
</ul>
Many of these problems are compounded by the high temperature of the exhaust gases, uneven flow patterns of the hot gases inside the heat exchanger, and operating variations such as frequent heating and cooling of the heat exchanger.<br />
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Dealing with industrial heating processes in which the exhaust gases are at high temperatures, or that contain all reactive constituents, or can be considered as harsh or contaminated are important considerations for the process engineer. If unsure, <a href="https://www.processsystemsdesign.com/" target="_blank">professional advice from knowledgeable consultants</a> should be sought to optimize the heating system. To discuss any process heating requirement you may have, contact <a href="https://www.processsystemsdesign.com/" target="_blank">Process Systems & Design</a> at <a href="https://www.processsystemsdesign.com/">https://www.processsystemsdesign.com</a> or by calling (410) 861-6437.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-9436248827612516022017-11-30T06:48:00.000-08:002017-11-30T06:52:56.262-08:00Improving Fan System Performance: A Sourcebook for Industry<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWFa38cDICKHmvjQr-iUmCK4BDh36hqgWIyTu2SY4GDFVdnRk4qdHwrN_9N7jS0NzWFXfB2okXR5QXk2FhIVGuHU2U4LWCY7tSh7oCNCMRRFLCMqnG-uw1YTkuDBYhTUeSE9ULKpC8-qQ/s1600/Fan-Systems-Process-Systems-Design.jpg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Fan System Performance" border="0" data-original-height="500" data-original-width="671" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWFa38cDICKHmvjQr-iUmCK4BDh36hqgWIyTu2SY4GDFVdnRk4qdHwrN_9N7jS0NzWFXfB2okXR5QXk2FhIVGuHU2U4LWCY7tSh7oCNCMRRFLCMqnG-uw1YTkuDBYhTUeSE9ULKpC8-qQ/s320/Fan-Systems-Process-Systems-Design.jpg" title="Fan System Performance" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Typical Fan System</td></tr>
</tbody></table>
<b>Fans are widely used in industrial and commercial applications</b>. From shop ventilation to material handling to boiler applications, fans are critical for process support and human health.<br />
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In manufacturing, fan reliability is critical to plant operation. For example, where fans serve material handling applications, fan failure will immediately create a process stoppage. In industrial ventilation applications, fan failure will often force a process to be shut down (although there is often enough time to bring the process to an orderly stoppage). Even in heating and cooling applications, fan operation is essential to maintain a productive work environment. Fan failure leads to conditions in which worker productivity and product quality declines. This is especially true for some production applications in which air cleanliness is critical to minimizing production defects (for example, plastics injection molding and electronic component manufacturing).<br />
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The document below, developed by the <a href="https://energy.gov/" target="_blank">US DOE</a> and the <a href="http://www.amca.org/" target="_blank">Air Movement and Control Association International</a> provides wide ranging information about fans used in industry. <a href="https://processsystemsdesign.com/images/psd/template/Improving-Fan-System-Performance-A-Sourcebook-for-Industry.pdf" target="_blank">You can also download your own full copy of this document from here</a>.<br />
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<div style="text-align: center;">
<iframe allowfullscreen="" frameborder="0" height="714" marginheight="0" marginwidth="0" scrolling="no" src="//www.slideshare.net/slideshow/embed_code/key/qSh5tJRcfWEXbb" style="border-width: 1px; border: 1px solid #ccc; margin-bottom: 5px; max-width: 100%;" width="668"> </iframe> <br />
<div style="margin-bottom: 5px;">
<strong> <a href="https://www.slideshare.net/Processsystemsdesign/improving-fan-system-performance-a-sourcebook-for-industry" target="_blank" title="Improving Fan System Performance: A Sourcebook for Industry">Improving Fan System Performance: A Sourcebook for Industry</a> </strong> from <strong><a href="https://www.slideshare.net/Processsystemsdesign" target="_blank">Process Systems & Design</a></strong> </div>
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-63262976717745359292017-11-27T08:53:00.000-08:002017-11-27T08:56:47.182-08:00Unique Rotating Dryer Design is Perfect for Forest and Agricultural ProductsThe exclusive technology <a href="https://processsystemsdesign.com/article_84_Dryer-One-Rotary-Dryers.cfm" target="_blank">DRYER ONE</a>, developed by Belgium company Technic One, enables the precise drying and processing of a large range of forest and agricultural products, in addition to the recovery of waste materials.<br />
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It operates bu loading the material to be dried onto a rotating plate through which passes a hot air flow. After a 360° rotation, the partially dried material is transferred onto a second plate where it is rotated again, thereby completing the drying process. Various control processes are used to ensure the good working and to reach the desired moisture content of the product.<br />
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Typical drying applications are wood waste, wood shavings, sawdust, maize, coffee grounds, brewer's grain, corn, soy, seeds, rice, and barley.<br />
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A visual understanding of the dryer operation is explained below:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIrmQr-VL99ICORmHeMH-Vq1Ckv-vw5mmEGwOleHJ1Gc9AxVodevSs4Yzo9odBG9BrtYKckHU7uPK3Kq2k_ynSgsp4X3dmFhTqGSSMsRflF4KhmrYLFSDv0hgEvLMbUcTY5gJ6LBAvNP4/s1600/Process-Systems-Design-Smart-Dryer-1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="500" data-original-width="450" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIrmQr-VL99ICORmHeMH-Vq1Ckv-vw5mmEGwOleHJ1Gc9AxVodevSs4Yzo9odBG9BrtYKckHU7uPK3Kq2k_ynSgsp4X3dmFhTqGSSMsRflF4KhmrYLFSDv0hgEvLMbUcTY5gJ6LBAvNP4/s320/Process-Systems-Design-Smart-Dryer-1.png" width="288" /></a></div>
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<ol>
<li><b>IN</b> - The lower rotating plate is loaded with the material to be dried.</li>
<li><b>LOWER LEVEL DRYING</b> - The material is rotated by 360°.</li>
<li><b>UP</b> - The material to be dried is transferred towards the upper plate by a bucket elevator or a vertical screw conveyor.</li>
<li><b>HIGHER LEVEL DRYING</b> - The material is rotated 360° by the upper rotating plate, moving in the opposite direction to that of the lower level plate. This exclusive technology ensures better distribution of heat and greater efficiency than other hot air drying techniques.</li>
<li><b>OUT</b> - The dried material is exited towards the packaging or storage area.</li>
<li><b>HOT AIR FLOW</b> - The hot air is sucked from the top to the bottom creating a counter current. It successively crosses the higher and lower level plates.</li>
<li><b>RETRIEVAL AND EXPULSION OF AIR SATURATED WITH MOISTURE</b> - After passing through the two plates the saturated air is pushed upwards for expulsion. If necessary, filters suitable for residual particles can be installed at the final stage of the process.</li>
</ol>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq7vb5aGIxVipxvffXOPD1QSGhHOCu8MpoWWQMVmKMQ8hgDU2_VDDtsiZMZdv1_fb1FWAM-SkSCOcY_WO2yh4yjkigjDVOo14piaYdegpmKYBleyxzhBE9w6vG3BsimRakALumfg0S8S8/s1600/Process-Systems-Design-Smart-Dryer-2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="548" data-original-width="450" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq7vb5aGIxVipxvffXOPD1QSGhHOCu8MpoWWQMVmKMQ8hgDU2_VDDtsiZMZdv1_fb1FWAM-SkSCOcY_WO2yh4yjkigjDVOo14piaYdegpmKYBleyxzhBE9w6vG3BsimRakALumfg0S8S8/s320/Process-Systems-Design-Smart-Dryer-2.png" width="262" /></a></div>
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<ol>
<li>Hot water is brought from a cogeneration unit.</li>
<li>The heat exchanger transfers the heat from the hot water into ambient air. The heated air is then drawn into the dryer.</li>
<li>Cooled water evacuation after exchange.</li>
<li>The incoming air is dry and hot (60-90°C)(140-194°F).</li>
<li>The reverse counter-current air flow (moving from the top to the bottom of the dryer) presses through material laying on the rotating plates, this largely prevents dust dispersion.</li>
<li>The outgoing cooled air (25-30°C)(77-86°F), almost completely saturated with moisture, is evacuated via the central chimney.</li>
<li>The first rotating plate gradually and partially evaporates the moisture.</li>
<li>Material is transferred from the lower plate to the higher plate via a bucket elevator or a vertical screw conveyor. During the transfer, the material is rotated and mixed, providing better quality and even drying.</li>
<li>The second rotating plate completes the drying process and allows the hot air to absorb residual moisture.</li>
</ol>
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<ol>
<li><b>ROTATION OF MATERIAL</b> - Each drying plate is equipped with a screw conveyor which thoroughly rotates and mixes the material to be dried. This process provides more even and better quality drying.</li>
<li><b>ROTATION SYSTEM</b> - Each rotating plate is driven by a gearmotor, which ensures a constant rotation speed with complete reliability.</li>
<li><b>PLATE COVERINGS</b> - The rotating plates are covered with a highly resistant synthetic grooved surface or stainless steel perforated sheeting. The load loss of the material to be dried is lower than that of the covering, leading to better diffusion of the hot air flow across the whole surface. Moisture can be extracted gradually, without thermal shock. The more even humidity level is one of the main advantages of DRYER ONE™. The coverings can easily and quickly be replaced.</li>
<li><b>ROTATING METAL PLATES</b> - The rotating plates have a stainless steel grated structure with a planarity much greater than that of conveyor belts. They have high resistance to load stress and corrosion. The grated structure is divided into segments of equal size, making it much easier to carry out maintenance work or replacements in the space of just a few minutes.</li>
</ol>
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For more information on the <a href="https://processsystemsdesign.com/article_84_Dryer-One-Rotary-Dryers.cfm" target="_blank">Dryer One</a> system, contact <b>Process Systems & Design</b> by <b>calling (410) 861-6437</b> or visiting <a href="https://www.processsystemsdesign.com/">https://www.processsystemsdesign.com</a>.</div>
Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-62642149582258095092017-11-08T05:55:00.000-08:002017-11-08T05:55:00.399-08:00Biomass for Power and Heat Generation<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTkfXud2Zmx75UU9PWE3sCTAj_9XJumSZqfqEMcs0Lpvxos-CiqEsOrL_BV1HD2EBrHFwRAZXFWlz68FLgIC9HfRW33jZX7HsZq6MgWyEKa9a5UXoevQb20CX7InDCEg4eUCy33PmVHyc/s1600/biomass-heating-power-plant-910240_640.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="459" data-original-width="640" height="229" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTkfXud2Zmx75UU9PWE3sCTAj_9XJumSZqfqEMcs0Lpvxos-CiqEsOrL_BV1HD2EBrHFwRAZXFWlz68FLgIC9HfRW33jZX7HsZq6MgWyEKa9a5UXoevQb20CX7InDCEg4eUCy33PmVHyc/s320/biomass-heating-power-plant-910240_640.jpg" width="320" /></a></div>
There are many potential advantages to using biomass instead of fossil fuels for meeting energy needs. Specific benefits depend upon the intended use and fuel source, but often include: greenhouse gas and other air pollutant reductions, energy cost savings, local economic development, waste reduction, and the security of a domestic fuel supply. In addition, biomass is more flexible (e.g., can generate both power and heat) and reliable (as a non-intermittent resource) as an energy option than many other sources of renewable energy.<br />
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Biomass fuels are typically used most efficiently and beneficially when generating both power and heat through CHP (<span style="font-size: 11pt;">combined heat and power)</span>. CHP, also known as cogeneration, is the simultaneous production of electricity and heat from a single fuel source, such as biomass/biogas, natural gas, coal, or oil. CHP provides:<br />
<ul>
<li>Distributed generation of electrical and/or mechanical power.</li>
<li>Waste-heat recovery for heating, cooling, or process applications.</li>
<li>Seamless system integration for a variety of technologies, thermal applications, and fuel types into existing building infrastructure.</li>
</ul>
CHP is not a single technology, but an integrated energy system that can be modified depending on the needs of the energy end user. The hallmark of all well-designed CHP systems is an increase in the efficiency of fuel use. By using waste heat recovery technology to capture a significant proportion of heat created as a byproduct in electricity generation, CHP systems typically achieve total system efficiencies of 60 to 80 percent for producing electricity and thermal energy. These efficiency gains improve the economics of using biomass fuels, as well as produce other environmental benefits. More than 60 percent of current biomass-powered electricity generation in the United States is in the form of CHP.<br />
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The industrial sector currently produces both steam or hot water and electricity from biomass in CHP facilities in the paper, chemical, wood products, and food-processing industries. These industries are major users of biomass fuels; utilizing the heat and steam in their processes can improve energy efficiency by more than 35 percent. The biggest industrial user of bioenergy is the forest products industry, which consumes 85 percent of all wood waste used for energy in the United States. Manufacturing plants that utilize forest products can typically generate more than half of their own energy from woody waste products and other renewable sources of fuel (e.g., wood chips, black liquor).<br />
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Most of the electricity, heat, and steam produced by industrial facilities are consumed on site; however, some manufacturers that produce more electricity than they need on site sell excess power to the grid. Wider use of biomass resources will directly benefit many companies that generate more residues (e.g., wood or processing wastes) than they can use internally. New markets for these excess materials may support business expansion as the residues are purchased for energy generation purposes or new profit centers of renewable energy production may diversify and support the core business of these companies.<br />
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Biomass Feedstocks<br />
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The success of any biomass-fueled CHP project is heavily dependent on the availability of a suitable biomass feedstock. Biomass feedstocks are widely available in both rural and urban settings and can include:<br />
<br />
Rural Resources:<br />
<ul>
<li>Forest residues and wood wastes</li>
<li>Crop residues Energy crops Manure biogas</li>
</ul>
Urban Resources:<br />
<ul>
<li>Urban wood waste</li>
<li>Wastewater treatment biogas</li>
<li>Municipal solid waste (MSW) and landfill gas (LFG)</li>
<li>Food processing residue</li>
</ul>
Feedstocks vary widely in their sources and fuel characteristics and therefore vary in typical considerations for their utilization. Various biomass resources can require different approaches to collection, storage, and transportation, as well as different considerations regarding the conversion process and power generation technology that they would most effectively fuel.<br />
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<b>Process Systems & Design</b> welcomes your inquiries in to biomass processing. With years of engineering experience in this field, PS&D is an outstanding engineering partner for any biomass-to-energy conversion process.<br />
<br />
<a href="http://processsystemsdesign.com/article_72_Contact.cfm" target="_blank">Contact Process Systems & Design</a> by visiting <a href="http://www.processsystemsdesign.com/">http://www.processsystemsdesign.com</a> or call (410) 861-6437.<br />
<br />Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-70669683703753134702017-10-23T17:41:00.002-07:002017-10-23T17:41:26.188-07:00Process Systems & Design: A Wide Range of Engineering Capabilities<div style="text-align: center;">
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-69649238279704017212017-10-18T12:17:00.000-07:002017-10-18T12:17:05.351-07:00A Leading Authority on E-Liquid Manufacturing Equipment<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZcFsESLHXvgE69hiAHGN_4tlMt2nlz1iWiXT4qLZuyaPRsRPVQZlRwtNbk0Yug4NFE2b2LdQdNRSJGV1-fn8zQn9dHemNYTKosWIlYbYoFMF3fV0ph5j9cbpcB8zPBUTntK6SA5cZCq0/s1600/vape-e-liquid.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="540" data-original-width="540" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZcFsESLHXvgE69hiAHGN_4tlMt2nlz1iWiXT4qLZuyaPRsRPVQZlRwtNbk0Yug4NFE2b2LdQdNRSJGV1-fn8zQn9dHemNYTKosWIlYbYoFMF3fV0ph5j9cbpcB8zPBUTntK6SA5cZCq0/s200/vape-e-liquid.jpg" width="200" /></a></div>
As an alternative to smoking tobacco, inhaling vaporized liquids containing nicotine, flavors and vegetable glycerin has become very popular. The name this new industry has been given is “<b>Vaping</b>” and the products used in electronic vaporizers is referred to as <b>E-Liquid</b>. E-Liquids are heated to vapor, then inhaled, and the various compounds (such as nicotine) are adsorbed by the mouth, nose and lungs.<br />
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Because of the obvious health concerns of inhaling flavor compounds, stabilizers, and other E-Liquid constituents, FDA (Food and Drug Administration) oversight is acute. Considering this, the E-Liquid industry must be prepared to implement strict cGMP manufacturing processes that include all aspects of production - from storage and blending, flow of ingredients, and finished product - with strict FDA record-keeping compliance.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCzDkkzuFMEZdCPDuvgf1jDD7cMpSBzL7-P4pFXAz4QBYnh5mvQ03Uf8KBLFuMGu-9qnFa74MqpJkVorYeEPDfUF04oXR_4yziLOXXLMySJVVam9BhnXzHx8u1fRyOiph4L1NyPxTE_7o/s1600/PSD-E-Liquid-Manufacturing-Equipment.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="758" data-original-width="1068" height="227" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCzDkkzuFMEZdCPDuvgf1jDD7cMpSBzL7-P4pFXAz4QBYnh5mvQ03Uf8KBLFuMGu-9qnFa74MqpJkVorYeEPDfUF04oXR_4yziLOXXLMySJVVam9BhnXzHx8u1fRyOiph4L1NyPxTE_7o/s320/PSD-E-Liquid-Manufacturing-Equipment.jpg" width="320" /></a>Since the E-Liquid/Vaping industry is relatively new, companies considering a move into producing and selling E-Liquids are finding it difficult to find <a href="http://processsystemsdesign.com/article_74_E-liquid-Vaping.cfm" target="_blank">experienced, qualified equipment designers and consultants</a>. Not only are their few qualified vendors, but the legislative constraints on the industry seem to change frequently. The right equipment partner needs to not only have the technical know-how to build safe, reliable, and efficient equipment, but they also must be on top of FDA and other governmental factors.<br />
<br />
<a href="http://processsystemsdesign.com/" target="_blank">Process Systems & Design</a>, located in Westminster, MD is one of the world’s leading experts in E-Liquid manufacturing. PS&D developed the first FDA compliant, safe, accurate, automated, and self-contained e-Liquid compounding system for the e-liquid/vaping industry. You can lean more about <b>Process Systems & Design</b> at <a href="http://www.processsystemsdesign.com/e-liquid">http://www.processsystemsdesign.com/e-liquid</a> or by calling (410) 861-6437.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-60728141367156616602017-10-09T11:01:00.000-07:002017-10-09T11:01:57.081-07:00Gypsum Processing for Cement, Plaster and Wallboard<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUo0Y5osYQHG-geykznASV4lVTPgvN_GQB3cSneBtCvyn1OBtfJybEaC0KTfCLFF-LNuphiV3L5Zqs_haQ_ijcMAO9QOja1Vnb9Tqf_av93wYhl3uatdN2ZC5IL0aDfw0JG9ze8keCxys/s1600/Gypsum-Process-Systems-Design.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="Gypsum" border="0" data-original-height="450" data-original-width="800" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUo0Y5osYQHG-geykznASV4lVTPgvN_GQB3cSneBtCvyn1OBtfJybEaC0KTfCLFF-LNuphiV3L5Zqs_haQ_ijcMAO9QOja1Vnb9Tqf_av93wYhl3uatdN2ZC5IL0aDfw0JG9ze8keCxys/s320/Gypsum-Process-Systems-Design.jpg" title="Gypsum" width="320" /></a></div>
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Gypsum is calcium sulfate dihydrate (CaSO4 2H2O), a white or gray naturally occurring mineral, and is used as a commercial and generic term for all calcium sulfate materials. Raw gypsum ore is processed into a variety of products such as a portland cement additive, soil conditioner, industrial and building plasters, and gypsum wallboard.<br />
<br />
Gypsum ore, from quarries and underground mines, is crushed and stockpiled near a plant. As needed, the stockpiled ore is further crushed and screened to about 50 millimeters (2 inches) in diameter. If the moisture content of the mined ore is greater than about 0.5 weight percent, the ore must be dried in a rotary dryer or a heated roller mill. Ore dried in a rotary dryer is conveyed to a roller mill, where it is ground to the extent that 90 percent of it is less than 149 micrometers (100 mesh). The ground gypsum exits the mill in a gas stream and is collected in a product cyclone. Ore is sometimes dried in the roller mill by heating the gas stream so that drying and grinding are accomplished simultaneously and no rotary dryer is needed. The finely ground gypsum ore is known as landplaster, which may be used as a soil conditioner. <br />
<br />
In most plants, landplaster is fed to kettle calciners or flash calciners, where it is heated to remove three-quarters of the chemically bound water to form stucco (CaSO4 1⁄2H2O). Calcination occurs at approximately 120° to 150°C (250° to 300°F) and 0.908 megagrams (Mg) (1 ton) of gypsum calcines to about 0.77 Mg (0.85 ton) of stucco. <br />
<br />
In kettle calciners, the gypsum is indirectly heated by hot combustion gas passed through flues in the kettle, and the stucco product is discharged into a "hot pit" located below the kettle. Kettle calciners may be operated in either batch or continuous mode. In flash calciners, the gypsum is directly contacted with hot gases, and the stucco product is collected at the bottom of the calciner. <br />
<br />
At some gypsum plants, drying, grinding, and calcining are performed in heated impact mills. In these mills hot gas contacts gypsum as it is ground. The gas dries and calcines the ore and then conveys the stucco to a product cyclone for collection. The use of heated impact mills eliminates the need for rotary dryers, calciners, and roller mills. <br />
<br />
Gypsum and stucco are usually transferred from one process to another by means of screw conveyors or bucket elevators. Storage bins or silos are normally located downstream of roller mills and calciners but may also be used elsewhere. <br />
<br />
In the manufacture of plasters, stucco is ground further in a tube or ball mill and then batch-mixed with retarders and stabilizers to produce plasters with specific setting rates. The thoroughly mixed plaster is fed continuously from intermediate storage bins to a bagging operation. <br />
<br />
In the manufacture of wallboard, stucco from storage is first mixed with dry additives such as perlite, starch, fiberglass, or vermiculite. This dry mix is combined with water, soap foam, accelerators, and shredded paper or pulpwood in a pin mixer at the head of a board forming line. The slurry is then spread between two paper sheets that serve as a mold. The edges of the paper are scored, and sometimes chamfered, to allow precise folding of the paper to form the edges of the board. As the wet board travels the length of a conveying line, the calcium sulfate hemihydrate combines with the water in the slurry to form solid calcium sulfate dihydrate, or gypsum, resulting in rigid board. The board is rough-cut to length, and it enters a multideck kiln dryer, where it is dried by direct contact with hot combustion gases or by indirect steam heating. The dried board is conveyed to the board end sawing area and is trimmed and bundled for shipment. Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-63204572239895247212017-09-28T14:54:00.000-07:002017-09-28T14:54:10.798-07:00The VIPER Automated, FDA Compliant, Self-contained e-Liquid Compounding System<a href="http://processsystemsdesign.com/" target="_blank">PS&D's</a> Viper is the first FDA compliant, safe, accurate, automated, and self-contained e-Liquid compounding system for the e-liquid vaping industry. <br />
<br />
The production system is integrated with a flexible batch management system that provides a platform for automatic control and electronic record-keeping to comply with FDA regulations 21 CFR 210, 211, and 11. Proven products from Rockwell Automation provides the core of control and information management system. It provides the authorized operator with a secure tool for designing flexible recipes that combine operator-entered and automatic data collection into a single work flow. In-process weights are collected automatically and used to manage the flow of ingredients and finished products between storage and blending vessels. System components, including motors and automatic valves are sequenced according to the recipes’ logic. Data are stored in a relational database management system for long-term storage and reporting. PS&D supports the information technologies associated with the recipe management and data collection processes through secure cloud-based computing and network communications platforms.<br />
<br />
For more information, visit http://www.processsystemsdesign.com/e-liquid or <b>call (410) 861-6437</b>.<br />
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-43344758712967923812017-09-12T06:53:00.002-07:002017-09-12T06:56:20.005-07:00From Biomass to Biofuel<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjszjEglvGEdoXTW7Dwj8cf2ym3rWvm9UUj4YfrXNF5GxwvHPHPylCWROGl-17vj57j_X6kS0vOP7H8uAxCFaQp1cOm8XsVPJ4FMvDXmtFeDCipVGdbguM0vOqXCG3BWwAw9zqYOuKeblA/s1600/Biomass-for-Fuel.jpeg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Biomass converted to gasoline" border="0" data-original-height="886" data-original-width="1181" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjszjEglvGEdoXTW7Dwj8cf2ym3rWvm9UUj4YfrXNF5GxwvHPHPylCWROGl-17vj57j_X6kS0vOP7H8uAxCFaQp1cOm8XsVPJ4FMvDXmtFeDCipVGdbguM0vOqXCG3BWwAw9zqYOuKeblA/s320/Biomass-for-Fuel.jpeg" title="Biomass converted to gasoline" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Biomass converted to gasoline (image courtesy of epa.gov)</td></tr>
</tbody></table>
<a href="http://processsystemsdesign.com/article_56_Biomass-Energy-Recovery.cfm" target="_blank">Biomass resources</a> run the gamut from corn kernels to corn stalks, from soybean and canola oils to animal fats, from prairie grasses to hardwoods, and even include algae.<br />
<br />
<div>
In the long run, we will need diverse technologies to make use of these different energy sources. Some technologies are already developed; others will be. Today, the most common technologies involve biochemical, chemical, and thermochemical conversion processes. <br />
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<br />
<br />
<br />
Ethanol, today’s largest volume biofuel, is produced through a <a href="http://processsystemsdesign.com/article_56_Biomass-Energy-Recovery.cfm" target="_blank">biochemical conversion process</a>. In this process, yeasts ferment sugar from starch and sugar crops into ethanol. Most of today’s ethanol is produced from cornstarch or sugarcane. But biochemical conversion techniques can also make use of more abundant “cellulosic” biomass sources such as grasses, trees, and agricultural residues. <br />
<br />
Researchers develop processes that use heat, pressure, chemicals, and enzymes to unlock the sugars in cellulosic biomass. The sugars are then fermented to ethanol, typically by using genetically engineered micro- organisms. Cellulosic ethanol is the leading candidate for replacing a large portion of U.S. petroleum use.<br />
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A much simpler chemical process is used to produce biodiesel. Today’s biodiesel facilities start with vegetable oils, seed oils, or animal fats and react them with methanol or ethanol in the presence of a catalyst. In addition, genetic engineering work has produced algae with a high lipid content that can be used as another source of biodiesel. <br />
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Algae are a form of biomass which could substantially increase our nation’s ability to produce domestic biofuels. Algae and plants can serve as a natural source of oil, which conventional petroleum refineries can convert into jet fuel or diesel fuel—a product known as “green diesel.” <br />
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Researchers also explore and develop thermochemical processes for <a href="http://processsystemsdesign.com/article_56_Biomass-Energy-Recovery.cfm" target="_blank">converting biomass to liquid fuels</a>. One such process is pyrolysis, which decomposes biomass by heating it in the absence of air. This produces an oil-like liquid that can be burned like fuel oil or re ned into chemicals and fuels, such as “green gasoline.” Thermochemical processes can also be used to pretreat biomass for conversion to biofuels. <br />
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Another thermochemical process is gasification. In this process, heat and a limited amount of oxygen are used to convert biomass into a hot synthesis gas. This “syngas” can be combusted and used to produce electricity in a gas turbine or converted to hydrocarbons, alcohols, ethers, or chemical products. In this process, biomass gasifiers can work side by side with fossil fuel gasifiers for greater flexibility and lower net greenhouse gas emissions.<br />
<br />
In the future, biomass-derived components such as carbohydrates, lignins, and triglycerides might also be converted to hydrocarbon fuels. Such fuels can be used in heavy-duty vehicles, jet engines, and other applications that need fuels with higher energy densities than those of ethanol or biodiesel.</div>
Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-14484546959298512682017-09-10T08:32:00.000-07:002017-09-10T08:45:25.845-07:00Batch Processing vs. Continuous Manufacturing in Pharmaceuticals<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgotOOvfbywN8vjypfDc7iKVfs87k1_v8IW1aH6itlYU5LDipo43JR0cJ2oGms30zI5bwUHUu8CijsrddJzjMvTqCmSP7zV2WT_kOKTB-x2ER6hGm37i6mIgr32rDlNG2Fnod1mfY2eiU0/s1600/medical-1905067_1280.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="678" data-original-width="734" height="184" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgotOOvfbywN8vjypfDc7iKVfs87k1_v8IW1aH6itlYU5LDipo43JR0cJ2oGms30zI5bwUHUu8CijsrddJzjMvTqCmSP7zV2WT_kOKTB-x2ER6hGm37i6mIgr32rDlNG2Fnod1mfY2eiU0/s200/medical-1905067_1280.jpg" width="200" /></a></div>
Not much has changed in pharmaceutical manufacturing over the last 50 years. While technological advancements in creating new drugs have been made, the pharmaceutical industry still relies heavenly on traditional step-by-step batch processing.<br />
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Alternatively, continuous manufacturing, which is the preferred manufacturing process in automotive, food & beverage, and refining industries – has been slow to gain acceptance in pharmaceutical production, largely because of high startup costs.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBAbGwgGDVuRjg8tMVz8QAaDeNiJfNNxB-x7jib2Mp48Mky1Ki5D60fgTMfAbVfH3012IHtplS9elZ4ztSyytgI5k69mdKiE0-jeyvWFP_tHJYOydmqYrF4JZW3Yp4r5wG1P4pNNJ_5dM/s1600/Batch-vs-Continuous.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Batch Processing vs. Continuous Manufacturing " border="0" data-original-height="622" data-original-width="1161" height="213" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBAbGwgGDVuRjg8tMVz8QAaDeNiJfNNxB-x7jib2Mp48Mky1Ki5D60fgTMfAbVfH3012IHtplS9elZ4ztSyytgI5k69mdKiE0-jeyvWFP_tHJYOydmqYrF4JZW3Yp4r5wG1P4pNNJ_5dM/s400/Batch-vs-Continuous.jpg" title="Batch Processing vs. Continuous Manufacturing " width="400" /></a></div>
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<b>Comparisons</b><br />
<h4>
<br />Batch Manufacturing:</h4>
All materials are charged before the start of processing and discharged at the end of<br />
processing.<br />
<br />
<ul>
<li>Examples: Bin blending, lyophilization, some reactions</li>
</ul>
<br />
<h4>
Continuous Manufacturing</h4>
Material is simultaneously charged and discharged from the process<br />
<br />
<ul>
<li>Examples: Petroleum refining, much of food processing</li>
</ul>
<br />
<b>VARIATIONS</b><br />
<h4>
<br />Semi-Batch (Fed-batch)Manufacturing</h4>
Materials are added during processing and discharged at the end of processing.<br />
<br />
<ul>
<li>Examples: Wet granulation, fermentation</li>
</ul>
<br />
<h4>
Semi-Continuous Manufacturing</h4>
Like continuous manufacturing, but for a discrete time period.<br />
<br />
<ul>
<li>Examples: Roller compaction, tablet compression</li>
</ul>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjW-NoY-CqnJk3d1qDwsqDAlEPev5JfCul2LZ5n8O6I7dIq3AMrucNFRDPdO2HVnIVsbkGqeERZUU-T-MJP2vb5H5cUUin-EC0Fb4w1BNW_dsG34_D6t6I0-tGxotZnLqiCuPTL_FyvU8s/s1600/Batch-Processing.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Batch Processing" border="0" data-original-height="857" data-original-width="1245" height="275" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjW-NoY-CqnJk3d1qDwsqDAlEPev5JfCul2LZ5n8O6I7dIq3AMrucNFRDPdO2HVnIVsbkGqeERZUU-T-MJP2vb5H5cUUin-EC0Fb4w1BNW_dsG34_D6t6I0-tGxotZnLqiCuPTL_FyvU8s/s400/Batch-Processing.jpg" title="Batch Processing" width="400" /></a></div>
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Although reliable, batch processing is viewed a slower manufacturing method for pharmaceuticals, and also less safe because of higher risk for contamination and errors between steps. Pharmaceutical manufacturers have no choice but to continually evaluate and implement the best possible production processes. Considering an estimated $50 billion per year is wasted on on inefficient processes in the pharmaceutical industry, it makes great sense to migrate toward continuous manufacturing.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1xdISaIDWrtMBeuEgnwFAWcY8mAhy_XV72aoVE1WUSIMou8kWwarhOtYMr5vvjaGq49UJhHk_M2WIH29hcAdaBZ2TWcQ11J_2GuAvxCO65caeLE9aQ36M5A7pSm6KD2THvztqqEsPpIU/s1600/Continuous-Manufacturing.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Continuous Manufacturing" border="0" data-original-height="850" data-original-width="1261" height="268" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1xdISaIDWrtMBeuEgnwFAWcY8mAhy_XV72aoVE1WUSIMou8kWwarhOtYMr5vvjaGq49UJhHk_M2WIH29hcAdaBZ2TWcQ11J_2GuAvxCO65caeLE9aQ36M5A7pSm6KD2THvztqqEsPpIU/s400/Continuous-Manufacturing.jpg" title="Continuous Manufacturing" width="400" /></a></div>
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<div>
Continuous manufacturing is faster, more efficient, and inherently safer. Improved safety is derived from rigid quality control requirements in continuous manufacturing. Considering this, the concern over large plant and equipment outlays looses is impact. Many experts maintain that continuous manufacturing is ultimately a far less costly production process (considering efficiency and safety), once the initial plant, equipment, and training costs are amortized.</div>
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-89886133780412575572017-09-05T14:23:00.000-07:002017-09-05T14:27:55.453-07:00Portland Cement Manufacturing<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge9lrpHmrrGYtWgOM62gFMWh_Jg51tGt7PSO1OjGrr9U_zYzG6rYrPBJeTcw6XCYi9nkh1OTIpqPM8scgQbStqN0rS1jWhJ0yNGkSPmOCVk1vqioBdFivdUQ3WzOPTGJ0o7nGj-hHO6xI/s1600/Cement.jpg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Bulk dry material handling" border="0" data-original-height="704" data-original-width="1523" height="147" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge9lrpHmrrGYtWgOM62gFMWh_Jg51tGt7PSO1OjGrr9U_zYzG6rYrPBJeTcw6XCYi9nkh1OTIpqPM8scgQbStqN0rS1jWhJ0yNGkSPmOCVk1vqioBdFivdUQ3WzOPTGJ0o7nGj-hHO6xI/s320/Cement.jpg" title="Bulk dry material handling" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Cement plant.</td></tr>
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Portland cement is a fine powder, gray or white in color, that consists of a mixture of hydraulic cement materials comprising primarily calcium silicates. More than 30 raw materials are known to be used in the manufacture of portland cement, and these materials can be divided into four distinct categories: calcareous, siliceous, argillaceous, and ferrifrous. These materials are chemically combined via pyroprocessing and subjected to subsequent mechanical processing operations to form gray and white portland cement. Gray portland cement is used for structural applications and is the more common type of cement produced. White portland cement has lower iron and manganese contents than gray portland cement and is used primarily for decorative purposes.<br />
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Portland cement, which consists of a mixture of the hydraulic cement minerals, calcium silicates, aluminates and aluminoferrites, and calcium sulfates, accounts for 95 percent of the hydraulic cement production in the United States. The balance of domestic cement production comprises primarily masonry cement. Both of these materials are produced in portland cement manufacturing plants.<br />
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<div>
The production of both portland and masonry cement can be divided into the following primary components: </div>
<div>
<ul>
<li>Raw materials acquisition and handling</li>
<li>Kiln feed preparation</li>
<li>Pyroprocessing</li>
<li>Finished cement grinding</li>
</ul>
</div>
<h4>
<br /></h4>
<h4>
Raw Materials Acquisition and Handling</h4>
<div>
Typically, these raw materials are obtained from open-face quarries, but underground mines or dredging operations are also used. Raw materials vary from facility to facility. The materials found in some quarries that supply raw materials for portland cement have a high degree of calcinated limestone, whereas the material from other limestone quarries must be blended with "cleaner" limestone to produce an acceptable product. In addition, pockets of pyrite, which significantly increase emissions of sulfur dioxide (SO2), can be found in deposits of limestone, clays, and shales used as raw materials for portland cement. Because a large fraction (approximately one third) of the mass of this primary material is converted to carbon dioxide (CO2) in the kiln, portland cement plants are located in close proximity to a raw material source whenever possible. Other metallic elements included in the raw feed mix are silicon, aluminum, and iron. These materials are obtained from ores and minerals such as sand, shale, clay, and iron ore. Again, these materials are most commonly extracted via open-pit quarries or mines, but they may be dredged or excavated from underwater deposits. <br />
<br />
Either gypsum or natural anhydrite, both of which are forms of calcium sulfate, is introduced to the process during the finish grinding operations described below. These materials are also excavated from quarries or mines. However, they are generally purchased from an external source, rather than obtained directly from a captive operation by the cement plant. In addition, the portland cement manufacturing industry is relying increasingly on replacing virgin materials as described above with waste materials or byproducts from other manufacturing operations, to the extent that such replacement can be implemented without adversely affecting plant operations or product quality. Materials that have been used include fly ash, mill scale, and metal smelting slags. <br />
<h4>
<br />Kiln Feed Preparation</h4>
The second step in portland cement manufacture is preparing the raw mix or kiln feed for the pyroprocessing operation. Raw material preparation includes a variety of blending and sizing operations that are designed to provide a feed with appropriate chemical and physical properties. The raw material processing operations differ somewhat for wet and dry processes, as described in the paragraphs below. <br />
<br />
Cement raw materials are received with an initial moisture content varying from 1 to more than 50 percent. If the facility uses dry process kilns, this moisture is usually reduced to less than 1 percent before or during grinding. Drying alone can be accomplished in impact dryers, drum dryers, paddle- equipped rapid dryers, air separators, or autogenous mills. However, drying can also be accomplished during grinding in ball-and-tube mills or roller mills. While thermal energy for drying can be supplied by exhaust gases from separate, direct-fired coal, oil, or gas burners, the most efficient and widely used source of heat for drying is the hot exit gases from the pyroprocessing system. <br />
<br />
Materials transport associated with raw milling systems can be accomplished by a variety of mechanisms, including screw conveyors, belt conveyors, drag conveyors, bucket elevators, air slide conveyors, and pneumatic conveying systems. The dry raw mix is pneumatically blended and stored in specially constructed silos until it is fed to the pyroprocessing system. <br />
<br />
In the wet process, water is added to the raw mill during the grinding of the raw materials in ball or tube mills, thereby producing a pumpable slip or slurry of approximately 65 percent solids. The slurry is agitated, blended, and stored in various kinds and sizes of cylindrical tanks or slurry basins until it is fed to the pyroprocessing system. <br />
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<h4>
Pyroprocessing</h4>
</div>
<div>
The heart of the portland cement manufacturing process is the pyroprocessing system. This system transforms the raw mix into clinkers, which are gray, glass-hard, spherically shaped nodules that range from 0.32 to 5.1 centimeters (cm) (0.125 to 2.0 inches [in.]) in diameter. The chemical reactions and physical processes that constitute the transformation are quite complex, but they can be viewed conceptually as the following sequential events: <br />
<ol>
<li>Evaporation of free water; </li>
<li>Evolution of combined water in the argillaceous components; </li>
<li>Calcination of the calcium carbonate (CaCO3) to calcium oxide (CaO); </li>
<li>Reaction of CaO with silica to form dicalcium silicate; </li>
<li>Reaction of CaO with the aluminum and iron-bearing constituents to form the liquid phase; </li>
<li>Formation of the clinker nodules; </li>
<li>Evaporation of volatile constituents (e.g., sodium, potassium, chlorides, and sulfates); and </li>
<li>Reaction of excess CaO with dicalcium silicate to form tricalcium silicate. </li>
</ol>
<div>
This sequence of events may be conveniently divided into four stages, as a function of location and temperature of the materials in the rotary kiln.<br />
<ol>
<li>Evaporation of uncombined water from raw materials as material temperature increases to 100 deg. C (212 deg. F); </li>
<li>Dehydration as the material temperature increases from 100 deg. C to approximately 430 deg. C (800 deg. F) to form oxides of silicon, aluminum, and iron; </li>
<li>Calcination, during which carbon dioxide (CO2) is evolved, between 900 deg. C (1650 deg. F) and 982 deg. C (1800 deg. F), to form CaO; and </li>
<li>Reaction of the oxides in the burning zone of the rotary kiln to form cement clinker at temperatures of approximately 1510 deg. C (2750 deg. F). </li>
</ol>
Rotary kilns are long, cylindrical, slightly inclined furnaces that are lined with refractory to protect the steel shell and retain heat within the kiln. The raw material mix enters the kiln at the elevated end, and the combustion fuels generally are introduced into the lower end of the kiln in a countercurrent manner. The materials are continuously and slowly moved to the lower end by rotation of the kiln. As they move down the kiln, the raw materials are changed to cementitious metal oxides by the direct heat exchange. The most commonly used kiln fuels are coal, natural gas, and occasionally oil. Many cement plants currently burn coal, but use of supplemental fuels such as waste solvents, scrap rubber, and petroleum coke has expanded in recent years.<br />
<br />
Five different processes are used in the portland cement industry to accomplish the pyroprocessing step: the wet process, the dry process (long dry process), the semidry process, the dry process with a preheater, and the dry process with a preheater/precalciner. Each of these processes accomplishes the physical/chemical steps defined above. However, the processes vary with respect to equipment design, method of operation, and fuel consumption. Generally, fuel consumption decreases in the order of the processes listed above. The paragraphs below briefly describe the process, starting with the wet process and then noting differences in the other processes. <br />
<br />
In the wet process and long dry process, all of the pyroprocessing activity occurs in the rotary kiln. Depending on the process type, kilns have length-to-diameter ratios in the range of 15:1 to 40:1. While some wet process kilns may be as long as 210 m (700 ft), many wet process kilns and all dry process kilns are shorter. Wet process and long dry process pyroprocessing systems consist solely of the simple rotary kiln. Usually, a system of chains is provided at the feed end of the kiln in the drying or preheat zones to improve heat transfer from the hot gases to the solid materials. As the kiln rotates, the chains are raised and exposed to the hot gases. Further kiln rotation causes the hot chains to fall into the cooler materials at the bottom of the kiln, thereby transferring the heat to the load. <br />
<br />
Dry process pyroprocessing systems have been improved in thermal efficiency and productive capacity through the addition of one or more cyclone-type preheater vessels in the gas stream after the rotary kiln. This system is called the preheater process. The vessels are arranged vertically, in series, and are supported by a structure known as the preheater tower. Hot exhaust gases from the rotary kiln pass countercurrently through the downward-moving raw materials in the preheater vessels. Compared with the simple rotary kiln, the heat transfer rate is significantly increased, the degree of heat utilization is more complete, and the process time is markedly reduced owing to the intimate contact of the solid particles with the hot gases. The improved heat transfer allows the length of the rotary kiln to be reduced. The hot gases from the preheater tower are often used as a source of heat for drying raw materials in the raw mill. Because the catch from the mechanical collectors, fabric filters, and/or electrostatic precipitators (ESP's) that follow the raw mill is returned to the process, these devices are considered to be production machines as well as pollution control devices. <br />
<br />
Additional thermal efficiencies and productivity gains have been achieved by diverting some fuel to a calciner vessel at the base of the preheater tower. This system is called the preheater/precalciner process. While a substantial amount of fuel is used in the precalciner, at least 40 percent of the thermal energy is required in the rotary kiln. The amount of fuel that is introduced to the calciner is determined by the availability and source of the oxygen for combustion in the calciner. Calciner systems sometimes use lower-quality fuels (e.g., less-volatile matter) as a means of improving process economics. <br />
<br />
Preheater and precalciner kiln systems often have a bypass system between the feed end of the rotary kiln and the preheater tower to remove the undesirable volatile constituents. Otherwise, the volatile constituents condense in the preheater tower and subsequently recirculate to the kiln. Buildup of these condensed materials can restrict process and gas flows. In a bypass system, a portion of the kiln exit gas stream is withdrawn and quickly cooled by air or water to condense the volatile constituents to fine particles. The solid particles, which are removed from the gas stream by fabric filters and ESP's, are then returned to the process. <br />
<br />
The semidry process is a variation of the dry process. In the semidry process, the water is added to the dry raw mix in a pelletizer to form moist nodules or pellets. The pellets then are conveyed on a moving grate preheater before being fed to the rotary kiln. The pellets are dried and partially calcined on the moving grate through which hot kiln exhaust gases pass. <br />
<br />
Regardless of the type of pyroprocess used, the last component of the pyroprocessing system is the clinker cooler. This process step recoups up to 30 percent of the heat input to the kiln system, locks in desirable product qualities by freezing mineralogy, and makes it possible to handle the cooled clinker with conventional conveying equipment. The more common types of clinker coolers are (1) reciprocating grate, (2) planetary, and (3) rotary. In these coolers, the clinker is cooled from about 1100 deg. C to 93 deg. C (2000 deg. F to 200 deg. F) by ambient air that passes through the clinker and into the rotary kiln for use as combustion air. However, in the reciprocating grate cooler, lower clinker discharge temperatures are achieved by passing an additional quantity of air through the clinker. Because this additional air cannot be utilized in the kiln for efficient combustion, it is vented to the atmosphere, used for drying coal or raw materials, or used as a combustion air source for the precalciner. <br />
<h4>
<br />Finished Cement Grinding</h4>
The final step in portland cement manufacturing involves a sequence of blending and grinding operations that transforms clinker to finished portland cement. Up to 5 percent gypsum or natural anhydrite is added to the clinker during grinding to control the cement setting time, and other specialty chemicals are added as needed to impart specific product properties. This finish milling is accomplished almost exclusively in ball or tube mills. Typically, finishing is conducted in a closed- circuit system with product sizing via air separation. </div>
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<a href="http://www.processsystemsdesign.com/" target="_blank">Process Systems & Design</a> are dry bulk material handling experts and can assist you in any sand, gravel, cement, or concrete handling requirement. <b>Contact them at (410) 861-6437</b> or visit their website at <a href="http://www.processsystemsdesign.com/">http://www.processsystemsdesign.com</a>.</div>
Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-33945964596780295702017-08-23T07:58:00.000-07:002017-08-23T07:58:04.066-07:00Sand and Gravel Processing
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<tr><td class="tr-caption" style="text-align: center;">Sand and Gravel Processing</td></tr>
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Deposits of sand and gravel, the unconsolidated granular materials resulting from the natural disintegration of rock or stone, are generally found in near-surface alluvial deposits and in subterranean and subaqueous beds. Sand and gravel are siliceous and calcareous products of the weathering of rocks and unconsolidated or poorly consolidated materials. Such deposits are common throughout the country. <br />
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<h3>
Construction Sand and Gravel</h3>
<h4>
Sand and gravel typically are mined in a moist or wet condition by open pit excavation or by dredging. </h4>
<div>
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<div>
Open pit excavation is carried out with power shovels, draglines, front end loaders, and bucket wheel excavators. In rare situations, light charge blasting is done to loosen the deposit. Mining by dredging involves mounting the equipment on boats or barges and removing the sand and gravel from the bottom of the body of water by suction or bucket-type dredges. After mining, the materials are transported to the processing plant by suction pump, earth mover, barge, truck, belt conveyors, or other means. <br />
<br />
Although significant amounts of sand and gravel are used for fill, bedding, subbase, and basecourse without processing, most domestic sand and gravel are processed prior to use. The processing of sand and gravel for a specific market involves the use of different combinations of washers, screens, and classifiers to segregate particle sizes; crushers to reduce oversized material; and storage and loading facilities.<br />
<br />
After being transported to the processing plant, the wet sand and gravel raw feed is stockpiled or emptied directly into a hopper, which typically is covered with a "grizzly" of parallel bars to screen out large cobbles and boulders. From the hopper, the material is transported to fixed or vibrating scalping screens by gravity, belt conveyors, hydraulic pump, or bucket elevators. The scalping screens separate the oversize material from the smaller, marketable sizes. Oversize material may be used for erosion control, reclamation, or other uses, or it may be directed to a crusher for size reduction, to produce crushed aggregate, or to produce manufactured sands. Crushing generally is carried out in one or two stages, although three-stage crushing may also be performed. Following crushing, the material is returned to the screening operation for sizing. <br />
<br />
The material that passes through the scalping screen is fed into a battery of sizing screens, which generally consists of either horizontal or sloped, and either single or multideck, vibrating<br />
screens. Rotating trommel screens with water sprays are also used to process and wash wet sand and gravel. Screening separates the sand and gravel into different size ranges. Water is sprayed onto the material throughout the screening process. After screening, the sized gravel is transported to stockpiles, storage bins, or, in some cases, to crushers by belt conveyors, bucket elevators, or screw conveyors. <br />
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The sand is freed from clay and organic impurities by log washers or rotary scrubbers. After scrubbing, the sand typically is sized by water classification. Wet and dry screening is rarely used to size the sand. After classification, the sand is dewatered using screws, separatory cones, or hydroseparators. Material may also be rodmilled to produce smaller sized fractions, although this practice is not common in the industry. After processing, the sand is transported to storage bins or stockpiles by belt conveyors, bucket elevators, or screw conveyors.<br />
<h3>
<br />Industrial Sand and Gravel</h3>
</div>
<h4>
Industrial sand and gravel typically are mined from open pits of naturally occurring quartz-rich sand and sandstone. </h4>
<div>
<br /></div>
<div>
Mining methods depend primarily on the degree of cementation of the rock. In some deposits, blasting is required to loosen the material prior to processing. The material may undergo primary crushing at the mine site before being transported to the processing plant.<br />
<br />
The mined rock is transported to the processing site and stockpiled. The material then is crushed. Depending on the degree of cementation, several stages of crushing may be required to achieve the desired size reduction. Gyratory crushers, jaw crushers, roll crushers, and impact mills are used for primary and secondary crushing. After crushing, the size of the material is further reduced to 50 micrometers or smaller by grinding, using smooth rolls, media mills, autogenous mills, hammer mills, or jet mills. The ground material then is classified by wet screening, dry screening, or air classification. At some plants, after initial crushing and screening, a portion of the sand may be diverted to construction sand use. <br />
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After initial crushing and screening, industrial sand and gravel are washed to remove unwanted dust and debris and are then screened and classified again. The sand (now containing 25 to 30 percent moisture) or gravel then goes to an attrition scrubbing system that removes surface stains from the material by rubbing in an agitated, high-density pulp. The scrubbed sand or gravel is diluted with water to 25 to 30 percent solids and is pumped to a set of cyclones for further desliming. If the deslimed sand or gravel contains mica, feldspar, and iron bearing minerals, it enters a froth flotation process to which sodium silicate and sulfuric acid are added. The mixture then enters a series of spiral classifiers where the impurities are floated in a froth and diverted to waste. The purified sand, which has a moisture content of 15 to 25 percent, is conveyed to drainage bins where the moisture content is reduced to about 6 percent. The material is then dried in rotary or fluidized bed dryers to a moisture content of less than 0.5 percent. The dryers generally are fired with natural gas or oil, although other fuels such as propane or diesel also may be used. After drying, the material is cooled and then undergoes final screening and classification prior to being stored and packaged for shipment. <br />
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<a href="http://processsystemsdesign.com/" target="_blank">Process Systems & Design</a> are experts in the processing of sand and gravel. Visit <a href="http://www.processsystemsdesign.com/">http://www.processsystemsdesign.com</a> or <b>call (410) 861-6437</b> with any inquiries or questions you may have.<br />
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-22081566803344642822017-08-17T06:41:00.001-07:002017-08-17T06:43:54.228-07:00Safe, Efficient, and Clean Operation of Belt Conveyors<b>Belt conveyors</b> are among the most commonly used piece of equipment at mineral processing operations. A conveyor, and the associated transfer points, can generate significant quantities of hazardous debris and respirable dust. Operations must control these emissions by containing, suppressing, or collecting the dust and debris mechanically, either before or after it spills or becomes airborne, giving special attention to transfer points.<br />
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A conveyor belt consists of many different parts as seen in Figure 1.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH26uCVrJby7trdwrJrnLm8qIlp8CJZjrGwJq9SXJmRolTa7-AALCiwosxoOq3KqvXBaDFczpsxvt4MunTav0s7fcrkT4yRy_Wch1FberSIRCjxsTO3GEw3NICG6JXPtidq5x20lM5pDA/s1600/Components-Belt-Conveyor-Process-Systems-Design.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="394" data-original-width="621" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH26uCVrJby7trdwrJrnLm8qIlp8CJZjrGwJq9SXJmRolTa7-AALCiwosxoOq3KqvXBaDFczpsxvt4MunTav0s7fcrkT4yRy_Wch1FberSIRCjxsTO3GEw3NICG6JXPtidq5x20lM5pDA/s400/Components-Belt-Conveyor-Process-Systems-Design.jpg" width="400" /></a></td></tr>
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<span style="font-family: "arial,bold"; font-size: 10.000000pt;">Figure 1 - Basic components of a conveyor belt. </span></div>
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There are three primary root causes for hazardous debris or fugitive dust emissions associated with conveyor belts: <b>spillage, carryback, and airborne dust </b>(Figure 2). Control of all three primary dust sources is necessary to eliminate hazardous debris and fugitive dust emissions.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4oU-wP1H0MZ2SuVv9ixFfrcJgM4R3P9cU1vSZIl8r6_hKE2Jdscdv0koAfjB6x4PxVqGuop0hqOrvHpsGBpxDsaIUGatusk1LGLqJU41K-P9QuIDlOgptib0u-b46ydi-tVon0pA-tjA/s1600/Emissions-Belt-Conveyor-Process-Systems-Design.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="212" data-original-width="641" height="131" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4oU-wP1H0MZ2SuVv9ixFfrcJgM4R3P9cU1vSZIl8r6_hKE2Jdscdv0koAfjB6x4PxVqGuop0hqOrvHpsGBpxDsaIUGatusk1LGLqJU41K-P9QuIDlOgptib0u-b46ydi-tVon0pA-tjA/s400/Emissions-Belt-Conveyor-Process-Systems-Design.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Fig. 2 - Types of fugitive dust emissions and debris from conveyor belts </td></tr>
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<b>Controlling Material Spillage</b><br />
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Material spillage from a conveyor belt is caused by a lack of material control, either at a transfer point or along the transfer route. Spillage along the transfer route is generally associated with carryback.<br />
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<b>Carryback </b><br />
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Material that sticks or clings to a conveyor belt after passing over the head pulley is called carryback. Carryback tends to fall from the belt as it passes over return idlers. This creates piles of material that require clean-up, which can increase worker dust exposure. Also, respirable portions of carryback can become airborne and increase fugitive dust exposure levels. The goal is to remove carryback before it is released into the air and becomes a source of contamination to the workers or creates piles of material that require clean-up. <br />
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The primary means of controlling carryback is to clean the belt as it passes over or past the head pulley (i.e. shortly after material is discharged from the belt). The two most common means of cleaning a conveyor belt of carryback are to mechanically "scrape" the belt via scrapers or brushes or to wash the belt.<br />
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<b>Water Sprays for Prevention of Airborne Dust</b><br />
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Wet spray systems, the use of water to control dust, may be classified into prevention applications and suppression applications. When properly designed and installed, water sprays are a cost-effective method of controlling dust from conveyors. The most common and effective practice for conveyor sprays is to wet the entire width of product on the belt. <br />
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To discuss this topic in greater detail, contact the <a href="http://processsystemsdesign.com/" target="_blank">experts at Process Systems & Design</a>. They'll be happy to share their decades of experience and knowledge with you.<br />
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<b>(410) 861-6437</b>Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-63078479490608831802017-08-15T14:18:00.000-07:002017-08-15T14:18:18.022-07:00The Cement Manufacturing Process<div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpjnNKNTHCnq8MFEiKEsPD1M1RCSpoSyZq-f5IxQFnZyY8UJQYRHyL73IpkuCuoEKQZ5G9G8R9k-fN7z11Kv49ctHEZnNlqhfgO2jnA8bqHXMyGPq6xJfyBUBAq-YVqQTgnEVjKqgomoI/s1600/Cement-Manufacturing-Process.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="879" data-original-width="1433" height="245" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpjnNKNTHCnq8MFEiKEsPD1M1RCSpoSyZq-f5IxQFnZyY8UJQYRHyL73IpkuCuoEKQZ5G9G8R9k-fN7z11Kv49ctHEZnNlqhfgO2jnA8bqHXMyGPq6xJfyBUBAq-YVqQTgnEVjKqgomoI/s400/Cement-Manufacturing-Process.jpg" width="400" /></a> </div>
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Cement is a finely ground powder which, when mixed with water, forms a hardening paste of calcium silicate hydrates and calcium aluminate hydrates. Cement is used in mortar (to bind together bricks or stones) and concrete (bulk rock-like building material made from cement, aggregate, sand, and water). By modifying the raw material mix and the temperatures utilized in manufacturing, compositional variations can be achieved to produce cements with different properties. In the U.S., the different varieties of cement are denoted per the American Society for Testing and Materials (ASTM) Specification C-150. <br />
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Cement is produced from raw materials such as limestone, chalk, shale, clay, and sand. These raw materials are quarried, crushed, finely ground, and blended to the correct chemical composition. Small quantities of iron ore, alumina, and other minerals may be added to adjust the raw material composition. The fine raw material is fed into a large rotary kiln (cylindrical furnace) which rotates while the contents are heated to extremely high temperatures. The high temperature causes the raw material to react and form a hard nodular material called “clinker”. Clinker is cooled and ground with approximately 5 percent gypsum and other minor additives to produce Portland cement. <br />
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The heart of clinker production is the rotary kiln where the pyroprocessing stage occurs. The rotary kiln is approximately 20 to 25 feet (ft) in diameter and from 150 ft to well over 300 ft long; the kiln is set at a slight incline and rotates one to three times per minute. The kiln is most often fired at the lower end (sometimes, mid-kiln firing is used and new units incorporate preheating as well as precalcining), and the raw materials are loaded at the upper end and move toward the flame as the kiln rotates. The materials reach temperatures of 2500°F to well above 3000°F in the kiln. Rotary kilns are divided into two groups, dry-process and wet-process, depending on how the raw materials are prepared. <br />
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In wet-process kilns, raw materials are fed into the kiln as a slurry with a moisture content of 30 to 40 percent. To evaporate the water contained in the feedstock, a wet-process kiln requires additional length (in comparison to a dry kiln). Additionally, to evaporate the water contained in the slurry, a wet kiln consumes nearly 33 percent more kiln energy when compared to a dry kiln. Wet-process kilns tend to be older operations as compared to dry-processes where raw materials are fed into the process as a dry powder. There are three major variations of dry- process kilns in operation in the U.S.: long dry (LD) kilns, preheater (PH) kilns, and preheater/precalciner (PH/PC) kilns. In PH kilns and PH/PC kilns, the early stages of pyroprocessing occur before the materials enter the rotary kiln. PH and PH/PC kilns tend to have higher production capacities and greater fuel efficiency compared to other types of cement kilns.<br />
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Three important processes occur with the raw material mixture during pyroprocessing. First, all moisture is driven from the materials. Second, the calcium carbonate in limestone dissociates into CO2 and calcium oxide (free lime); this process is called calcination. Third, the lime and other minerals in the raw materials react to form calcium silicates and calcium aluminates, which are the main components of clinker. This third step is known as clinkering or sintering. The formation of clinker concludes the pyroprocessing stage. <br />
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Once the clinker is formed in the rotary kiln, it is cooled rapidly to minimize the formation of a glass phase and ensure the maximum yield of alite (tricalcium silicate) formation, an important component for the hardening properties of cement. The main cooling technologies are either the grate cooler or the tube or planetary cooler. In the grate cooler, the clinker is transported over a reciprocating grate through which air flows perpendicular to the flow of clinker. In the planetary cooler (a series of tubes surrounding the discharge end of the rotary kiln), the clinker is cooled in a counter-current air stream. Reciprocating type grate coolers can also be used to cool the clinker. The cooling air is used as secondary combustion air for the kiln to improve efficiency since the cooling air has been preheated during the process of cooling the clinker.<br />
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After cooling, the clinker can be stored in the clinker dome, silos, bins, or outside in storage piles. The material handling equipment used to transport clinker from the clinker coolers to storage and then to the finish mill is similar to that used to transport raw materials (e.g. belt conveyors, deep bucket conveyors, and bucket elevators). To produce powdered cement, the nodules of clinker are ground to the consistency of powder. Grinding of clinker, together with additions of approximately 5 percent gypsum to control the setting properties of the cement can be done in ball mills, ball mills in combination with roller presses, roller mills, or roller presses. While vertical roller mills are feasible, they have not found wide acceptance in the U.S. Coarse material is separated in a classifier that is re-circulated and returned to the mill for additional grinding to ensure a uniform surface area of the final product. <br />
<br />Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-29712654836830937432017-07-22T11:27:00.001-07:002017-07-24T04:55:21.246-07:00Process Systems and Design: A Little Shameless Self PromotionA little video promoting our plant engineering and design services .. thanks for indulging us!<br />
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-17679470592326699882017-07-12T07:02:00.000-07:002017-07-12T07:09:39.667-07:00The Ethanol Production Process<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkxDmjj2Uli1Tq3DkOijc5f5xTa1fhPf_jlN5toFy7zfkGPeu9ISodKyIo0Og_HH5uBsM1YOtTrraHuvvF_RE9EI1YI-hWF3ieZwr-RrFIiR7D7cYAi698ZdwMHqUtIy_oJxkwmudjGJg/s1600/bigstock-Ethanol-Plant-513967.jpg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Ethanol Plant" border="0" data-original-height="984" data-original-width="1600" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkxDmjj2Uli1Tq3DkOijc5f5xTa1fhPf_jlN5toFy7zfkGPeu9ISodKyIo0Og_HH5uBsM1YOtTrraHuvvF_RE9EI1YI-hWF3ieZwr-RrFIiR7D7cYAi698ZdwMHqUtIy_oJxkwmudjGJg/s320/bigstock-Ethanol-Plant-513967.jpg" title="Ethanol Plant" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Ethanol Plant</td></tr>
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Though new technology may eventually blur the distinction between them, ethanol is produced by one of two processes: wet milling and dry milling. Wet mills are more expensive to build, are more versatile in terms of the products they can produce, yield slightly less ethanol per bushel, and have more valuable co-products. Wet milling initially accounted for most of the ethanol fuel production in the United States, but new construction has shifted to dry mills, partly because dry mills cost less to build. <br />
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Dry-milling plants have higher yields of ethanol. The wet mill is more versatile, though, because the starch stream, being nearly pure, can be converted into other products (for instance, high-fructose corn syrup (HFCS)). Co-product output from the wet mill is also more valuable. <br />
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In each process, the corn is cleaned before it enters the mill. In the dry mill, the milling step consists of grinding the corn and adding water to form the mash. In the wet mill, milling and processing are more elaborate because the grain must be separated into its components. First, the corn is steeped in a solution of water and sulfur dioxide (SO2) to loosen the germ and hull fiber. This 30- to 40-hour extra soaking step requires additional tanks that contribute to the higher construction costs. Then the germ is removed from the kernel, and corn oil is extracted from the germ. The remaining germ meal is added to the hulls and fiber to form the corn gluten feed (CGF) stream. Gluten, a high-protein portion of the kernel, is also separated and becomes corn gluten meal (CGM), a high-value, high-protein (60 percent) animal feed. The corn oil, CGF, CGM, and other products that result from the production of ethanol are termed co-products. <br />
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Unlike in dry milling, where the entire mash is fermented, in wet milling only the starch is fermented. The starch is then cooked, or liquefied, and an enzyme added to hydrolyze, or segment, the long starch chains. In dry milling, the mash, which still contains all the feed co-products, is cooked and an enzyme added. In both systems a second enzyme is added to turn the starch into a simple sugar, glucose, in a process called saccharification. Saccharification in a wet mill may take up to 48 hours, though it usually requires less time, depending on the amount of enzyme used. In modern dry mills, saccharification has been combined with the fermentation step in a process called simultaneous saccharification and fermentation (SSF). <br />
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Glucose is then fermented into ethanol by yeast (the SSF step in most dry- milling facilities). The mash must be cooled to at least 95deg. F before the yeast is added. The yeast converts the glucose into ethanol, carbon dioxide (CO2), and small quantities of other organic compounds during the fermentation process. The yeast, which produces almost as much CO2 as ethanol, ceases fermenting when the concentration of alcohol is between 12 and 18 percent by volume, with the average being about 15 percent. An energy-consuming process, the distillation step, is required to separate the ethanol from the alcohol-water solution. This two-part step consists of primary distillation and dehydration. Primary distillation yields ethanol that is up to 95-percent free of water. Dehydration brings the concentration of ethanol up to 99 percent. Finally, gasoline is added to the ethanol in a step called “denaturing,” making it unfit for human consumption when it leaves the plant. <br />
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The co-products from wet milling are corn oil and the animal feeds corn gluten feed (CGF) and corn gluten meal (CGM). Dry milling production leaves, in addition to ethanol, distiller’s dried grains with solubles (DDGS). The feed co-products must be concentrated in large evaporators and then dried. The CO2 may or may not be captured and sold. <br />
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<span style="font-size: x-small;">Reprinted from USDA publication “New Technologies in Ethanol Production”</span>Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-3770892011088953082017-06-30T06:20:00.000-07:002017-06-30T06:20:11.448-07:00Happy Fourth of July from PSD<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcnTzxjB1ooeGgkkVEYAgb5sm435I7VqWVTif0Iv6Ov_pn3tl8gTs6bvuEWlei3GD8EsxCgot8vG-cdd_3u-7bUJDnU5Us-EH59xQdty8w4F1DCFcb9ZDg_Jlh7a12CSEgitjD8_czPzU/s1600/US-original-Declaration-1776.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="516" data-original-width="1014" height="162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcnTzxjB1ooeGgkkVEYAgb5sm435I7VqWVTif0Iv6Ov_pn3tl8gTs6bvuEWlei3GD8EsxCgot8vG-cdd_3u-7bUJDnU5Us-EH59xQdty8w4F1DCFcb9ZDg_Jlh7a12CSEgitjD8_czPzU/s320/US-original-Declaration-1776.jpg" width="320" /></a></div>
"We hold these truths to be self-evident, that all men are created equal, that they are endowed by their Creator with certain unalienable Rights, that among these are Life, Liberty and the pursuit of Happiness. — That to secure these rights, Governments are instituted among Men, deriving their just powers from the consent of the governed, — That whenever any Form of Government becomes destructive of these ends, it is the Right of the People to alter or to abolish it, and to institute new Government, laying its foundation on such principles and organizing its powers in such form, as to them shall seem most likely to effect their Safety and Happiness."<br />
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THOMAS JEFFERSON, Declaration of IndependenceAnonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-17409503721549522182017-06-27T06:24:00.000-07:002017-06-27T06:25:14.856-07:00Dust Collection Systems in Mineral Processing Plants<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgff4U6VLCRFIQ43v6AQmKfu9VihiwowwTNjSSlGEyZ6wPS_14jwaSMH8glr_B5r8G9D1dEdNwfsERrBOply829Lbfv6R92XBZbpquOw16sdSys87CQ6_EYoI_dGxbbyFeAIDCzOTCOFpw/s1600/dust-control-systems-process-systems-design.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="Dust collection systems in mining" border="0" data-original-height="314" data-original-width="534" height="188" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgff4U6VLCRFIQ43v6AQmKfu9VihiwowwTNjSSlGEyZ6wPS_14jwaSMH8glr_B5r8G9D1dEdNwfsERrBOply829Lbfv6R92XBZbpquOw16sdSys87CQ6_EYoI_dGxbbyFeAIDCzOTCOFpw/s320/dust-control-systems-process-systems-design.jpg" title="Dust collection systems in mining" width="320" /></a></div>
<b>Dust collection systems</b> are the most widely used engineering control technique employed by mineral processing plants to control dust and lower workers' respirable dust exposure. A well- integrated dust collection system has multiple benefits, resulting in a dust-free environment that increases productivity and reclaims valuable product.<br />
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The most common dust control techniques at mineral processing plants utilize <b>local exhaust ventilation systems (LEVs)</b>. These systems capture dust generated by various processes such as crushing, milling, screening, drying, bagging, and loading, and then transport this dust via ductwork to a dust collection filtering device. By capturing the dust at the source, it is prevented from becoming liberated into the processing plant and contaminating the breathing atmosphere of the workers.<br />
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LEV systems use a negative pressure exhaust ventilation technique to capture the dust before it escapes from the processing operation. Effective systems typically incorporate a capture device (enclosure, hood, chute, etc.) designed to maximize the collection potential.<br />
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As part of a dust collection system, LEVs possess a number of advantages:<br />
<ul>
<li>the ability to capture and eliminate very fine particles that are difficult to control using wet suppression techniques;</li>
<li>the option of reintroducing the material captured back into the production process or discarding the material so that it is not a detriment later in the process; and</li>
<li>consistent performance in cold weather conditions because of not being greatly impacted by low temperatures, as are wet suppression systems.</li>
</ul>
In addition, LEVs may be the only dust control option available for some operations whose product is hygroscopic or suffers serious consequences from even small percentages of moisture (e.g., clay or shale operations).<br />
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In most cases, dust is generated in obvious ways. Anytime an operation is transporting, refining, or processing a dry material, there is a great likelihood that dust will be generated. It also follows that once the dust is liberated into the plant environment, it produces a dust cloud that may threaten worker health. In addition, high dust levels can impede visibility and thus directly affect the safety of workers.<br />
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The five areas that typically produce dust that must be controlled are as follows:<br />
<ol>
<li>The transfer points of conveying systems, where material falls while being transferred to another piece of equipment. Examples include the discharge of one belt conveyor to another belt conveyor, storage bin, or bucket elevator.</li>
<li>Specific processes such as crushing, drying, screening, mixing, blending, bag unloading, and truck or railcar loading.</li>
<li>Operations involving the displacement of air such as bag filling, palletizing, or pneumatic filling of silos.</li>
<li>Outdoor areas where potential dust sources are uncontrolled, such as core and blast hole drilling.</li>
<li>Outdoor areas such as haul roads, stockpiles, and miscellaneous unpaved areas where potential dust-generating material is disturbed by various mining-related activities and high-wind events.</li>
</ol>
While areas 4 and 5 can be significant sources of dust, they are generally not included in plant or mill ventilation systems design because of the vast area encompassed and the unpredictability of conditions. Therefore, dust control by methods alternative to LEVs is required.<br />
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Dust control systems involve multiple engineering decisions, including the efficient use of available space, the length of duct runs, the ease of returning collected dust to the process, the necessary electrical requirements, and the selection of optimal filter and control equipment. Further, key decisions must be made about whether a centralized system or multiple systems are best for the circumstances. Critical engineering decisions involve defining the problem, selecting the best equipment for each job, and designing the best dust collection system for the particular needs of an operation.<br />
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For more information on dust control systems, contact <a href="http://processsystemsdesign.com/">Process Systems Design</a> by visiting <a href="http://processsystemsdesign.com/">http://processsystemsdesign.com</a> or <b>calling (410) 861-6437</b>.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-6266600673691773702017-06-22T07:36:00.005-07:002017-06-22T07:36:48.237-07:00Equipment Used in Crushed Stone Processing<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmVc5FdQMA3ZY3y3YOHZ1hOcpOnSKi_Wpju_-wiWPc29hDhobCpnrmjVNAcLeSthuR3G_kh3ofzhyphenhyphenpRLMQxN03cfcbwOxwtxTI6sa8EPRHs3fovpsv2y3Db-FSDt6Xw3qbkvlZhby5tr4/s1600/processing-crushed-stone.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img alt="Crushed Stone Processing" border="0" data-original-height="720" data-original-width="1280" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmVc5FdQMA3ZY3y3YOHZ1hOcpOnSKi_Wpju_-wiWPc29hDhobCpnrmjVNAcLeSthuR3G_kh3ofzhyphenhyphenpRLMQxN03cfcbwOxwtxTI6sa8EPRHs3fovpsv2y3Db-FSDt6Xw3qbkvlZhby5tr4/s320/processing-crushed-stone.jpg" title="Crushed Stone Processing" width="320" /></a></div>
Major rock types processed by the crushed stone industry include limestone, granite, dolomite, traprock, sandstone, quartz, and quartzite. Minor types include calcareous marl, marble, shell, and slate. Major mineral types processed by the pulverized minerals industry, a subset of the crushed stone processing industry, include calcium carbonate, talc, and barite. Industry classifications vary considerably and, in many cases, do not reflect actual geological definitions.<br />
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Rock and crushed stone products generally are loosened by drilling and blasting and then are loaded by power shovel or front-end loader into large haul trucks that transport the material to the processing operations. Techniques used for extraction vary with the nature and location of the deposit. Processing operations may include crushing, screening, size classification, material handling and storage operations. All of these processes can be significant sources of PM and PM-10 emissions if uncontrolled.<br />
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Quarried stone normally is delivered to the processing plant by truck and is dumped into a bin. A feeder or screens separate large boulders from finer rocks that do not require primary crushing, thus reducing the load to the primary crusher. Jaw, impactor, or gyratory crushers are usually used for initial reduction. The crusher product, normally 7.5 to 30 centimeters (3 to 12 inches) in diameter, and the grizzly throughs (undersize material) are discharged onto a belt conveyor and usually are conveyed to a surge pile for temporary storage or are sold as coarse aggregates.<br />
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The stone from the surge pile is conveyed to a vibrating inclined screen called the scalping screen. This unit separates oversized rock from the smaller stone. The undersized material from the scalping screen is considered to be a product stream and is transported to a storage pile and sold as base material. The stone that is too large to pass through the top deck of the scalping screen is processed in the secondary crusher. Cone crushers are commonly used for secondary crushing (although impact crushers are sometimes used), which typically reduces material to about 2.5 to 10 centimeters (1 to 4 inches). The material (throughs) from the second level of the screen bypasses the secondary crusher because it is sufficiently small for the last crushing step. The output from the secondary crusher and the throughs from the secondary screen are transported by conveyor to the tertiary circuit, which includes a sizing screen and a tertiary crusher.<br />
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Tertiary crushing is usually performed using cone crushers or other types of impactor crushers. Oversize material from the top deck of the sizing screen is fed to the tertiary crusher. The tertiary crusher output, which is typically about 0.50 to 2.5 centimeters (3/16th to 1 inch), is returned to the sizing screen. Various product streams with different size gradations are separated in the screening operation. The products are conveyed or trucked directly to finished product bins, to open area stock piles, or to other processing systems such as washing, air separators, and screens and classifiers (for the production of manufactured sand).<br />
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Some stone crushing plants produce manufactured sand. This is a small-sized rock product with a maximum size of 0.50 centimeters (3/16th inch). Crushed stone from the tertiary sizing screen is sized in a vibrating inclined screen (fines screen) with relatively small mesh sizes.<br />
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Oversized material is processed in a cone crusher or a hammermill (fines crusher) adjusted to produce small diameter material. The output is returned to the fines screen for resizing.<br />
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In certain cases, stone washing is required to meet particulate end product specifications or demands.<br />
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For more information on equipment designed for processing crushed stone, visit <a href="http://www.processsystemsdesign.com/" target="_blank">Process Systems Design</a> at <a href="http://www.processsystemsdesign.com/">http://www.processsystemsdesign.com</a> or call (410) 861-6437.Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.comtag:blogger.com,1999:blog-1565945151279922834.post-82964411616664733932017-06-08T12:00:00.000-07:002017-06-08T12:00:10.839-07:00Dilute Phase Pneumatic Conveying<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3SqhiI_z8UpIxrKg5aoGbLXdll0YRinFiorU_SXpYRWIt4iJNRiJgauy1Qsxt3AGdZirWB0q2tCkIaQLExfqOPzyQXo4t3SuQB1UeWzE7sr356zt8oI6P7HcX2RCzSKBfCXow6PpptEc/s1600/DILUTE+PHASE+CONVEYING.png" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img alt="Dilute Phase Pneumatic Conveying" border="0" data-original-height="334" data-original-width="707" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3SqhiI_z8UpIxrKg5aoGbLXdll0YRinFiorU_SXpYRWIt4iJNRiJgauy1Qsxt3AGdZirWB0q2tCkIaQLExfqOPzyQXo4t3SuQB1UeWzE7sr356zt8oI6P7HcX2RCzSKBfCXow6PpptEc/s320/DILUTE+PHASE+CONVEYING.png" title="Dilute Phase Pneumatic Conveying" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Dilute Phase Pneumatic Conveying</td></tr>
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One of the most popular methods of moving solids in the chemical industry is <b><a href="http://processsystemsdesign.com/bulk-handling-systems-equipment/pneumatic-conveying-equipment/" target="_blank">pneumatic conveying</a></b>. Pneumatic conveying refers to the moving of solids suspended in or forced by a gas stream through horizontal and/or vertical pipes. Pneumatic conveying can be used for particles ranging from fine powders to pellets and bulk densities of 16 to 3200 kg/m3 (1 to 200 lb/ft3).<br />
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Considering designing a pneumatic conveying system yourself? Probably not a good idea. There's as much art involved as there is science and such a design should be left to professionals. Consider that even different grades of the same material have been known to convey differently. Testing is a must (as you'll see from the method below). Before you can even make any good judgements from the method presented here, you need to know solid friction factor for your solids (which we'll discuss later) and the minimum gas velocity required to move your particles. So, if you're involved in designing a system from the ground up, <a href="http://processsystemsdesign.com/" target="_blank">seek assistance from reputable people in the field of conveying</a>. If you're already familiar with your solids, the method below can be used to examine the pressure loss expected in your system. The method presented here is very good and has been stood the test of real systems over time.<br />
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Read the full white paper (courtesy of <a href="http://processsystemsdesign.com/" target="_blank">Process Systems & Design</a>) below:</div>
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<iframe allowfullscreen="" frameborder="0" height="714" marginheight="0" marginwidth="0" scrolling="no" src="//www.slideshare.net/slideshow/embed_code/key/MtnhRh6FzINaJq" style="border-width: 1px; border: 1px solid #ccc; margin-bottom: 5px; max-width: 100%;" width="668"> </iframe> <br />
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<strong> <a href="https://www.slideshare.net/Processsystemsdesign/dilute-phase-conveying" target="_blank" title="Dilute Phase Conveying">Dilute Phase Conveying</a> </strong> from <strong><a href="https://www.slideshare.net/Processsystemsdesign" target="_blank">Process Systems & Design</a></strong> </div>
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Anonymoushttp://www.blogger.com/profile/14666263898658209864noreply@blogger.com