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Controlling dust emissions in bulk loading

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An analysis of the four most common forms of bulk loading & unloading. Conducts a pros & cons analysis of each option, to give insight on which technique is most suitable for use in your loading process.

Published in: Engineering
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Controlling dust emissions in bulk loading

  1. 1. The loading of bulk materials into trucks, railcars, barges, ships or stockpiles is fraught with health, safety and environmental issues.
  2. 2. The loading of bulk materials into trucks, railcars, barges, ships or stockpiles is fraught with health, safety and environmental issues. Dust emissions in bulk loading terminals can lead to: • Employee respiration problems. • Workplace slip hazards. • Propagation of a potentially explosive atmosphere. • Contamination to local neighborhoods & waterways among others.
  3. 3. When material is discharged in mass flow, dust becomes airborne due to impact forces, air entrainment and friction between material particles. This is exasperated by the displacement of air within vessels, which often creates clouds of unmanageable dust in the loading area.
  4. 4. Over the decades, more strict regulation has forced companies to find solutions for decreasing or eliminating the presence of fugitive dust in loading processes.
  5. 5. Currently, there are many methods being used across manufacturing industries to reduce dust emissions. The most common practices include: • Loading Socks • Telescopic Chutes • Dust Suppression Hoppers • Cascading Chutes
  6. 6. Pros Cons Flexible. Low cost. Wears quickly. Cannot be automated. Does not control displaced air at the point of loading. A cylindrical tube of fabric sewn to be tapered – much like that of a windsock. Loading socks are typically made from canvas or polyurethane fabric. Loading Socks
  7. 7. Pros Cons Longer service life than loading socks. Retractable. Can “follow the load” and progressively retract. Heavy, high-plugged load that creates dust on material impact. Does not control displaced air at the point of loading. Telescopic Chutes A tube-in-tube chute that travels downward to load, and upward to clear the transport vessel. Made from metal.
  8. 8. Pros Cons A cost-effective solution for certain materials and applications. Heavy, high-plugged load that creates dust on material impact. Does not control displaced air at the point of loading. Dust Suppression Hoppers A hopper that attempts to lessen the agitation of particles, in order to reduce dust.
  9. 9. Pros Cons Can eliminate the need for a dust collector (in open loading applications). Is a “soft loading” solution, which reduces material degradation. High acquisition cost. Heavy and oversized to overcome capacity restraints. Not effective for closed vessels without dust collection systems. Does not control displaced air at the point of loading. Cascading Chutes Designed with angled cones to reduce the velocity of material flow, thus reducing frictional forces and material impact.
  10. 10. All four of these methods can be effective in limited applications, but all fail to address the primary causes of fugitive dust.
  11. 11. How to Manage Displaced Air & Dust In the loading process, the extraction of displaced air is key to dust management. Vortex loading equipment is specifically designed to control this problematic mixture of air and dust, to address the health, safety, and environmental issues faced by industries today. Vortex retractable loading spouts are designed per the demands of each application to address air displacement at the source.
  12. 12. Enclosed Loading The Vortex loading spout design seals off the vessel’s loading hatch and is equipped with a filter to guarantee dust-free loading by means of a vacuum pull. The displaced air and dust mixture is then aspirated out of the enclosed vessel via an in-line filter, allowing the dust to be reintroduced into the material flow. This creates a completely closed cycle, which minimizes material loss.
  13. 13. Open Loading This approach can also be used in open loading circumstances, such as truck, railcar, barge, or stockpiling. This is achieved by attaching a dust skirt at the outlet of the spout, which rests atop the product pile and seals the vacuum pull as the spout fills.
  14. 14. The Vortex loading spout design is beneficial for its flexibility and scalability. It can be used to handle a wide variety of abrasive and non-abrasive powder, pellet, or granular materials by modifying spout construction materials and tolerances. In certain cases, the spout’s base design can be slightly altered to a telescopic tube configuration, with a multistage filter near the outlet of the spout. Certain configurations are even suitable for use in food-grade applications.
  15. 15. Model Max. Capacity Loading Type Max. Extended Travel Ex-Proof Standard Vortex VOS-10 Loading Spout 100 ftᶾ/min (170 mᶾ/hr) Open 10 ft (3 m) ATEX, Class II, Div II & Div I Vortex VOS-25 Loading Spout 250 ftᶾ/min (425 mᶾ/hr) Open 20 ft (6 m) ATEX, Class II, Div II & Div I Vortex VOS-40 Loading Spout 400 ftᶾ/min (680 mᶾ/hr) Open 40 ft (12 m) ATEX, Class II, Div II & Div I Vortex VES-10 Loading Spout 100 ftᶾ/min (170 mᶾ/hr) Enclosed 10 ft (3 m) ATEX, Class II, Div II & Div I Vortex VES-25 Loading Spout 250 ftᶾ/min (425 mᶾ/hr) Enclosed 20 ft (6 m) ATEX, Class II, Div II & Div I Vortex VES-40 Loading Spout 400 ftᶾ/min (680 mᶾ/hr) Enclosed 40 ft (12 m) ATEX, Class II, Div II & Div I *Note: In cases where capacity exceeds 400 ftᶾ/min (680 mᶾ/hr), Vortex has larger engineered loading spouts with throughputs exceeding 2,500 ftᶾ/min (4,250 mᶾ/hr).
  16. 16. Controlling dust at loading terminals is a critical concern for many companies. Sourcing equipment that does not manage displaced air and dust can lead to costly and prolonged health, safety, and environmental issues.
  17. 17. Vortex (888) 829-7821 vortex@vortexglobal.com www.vortexglobal.com Salina, KS – United States Vortex Global 44 (0) 132-572-8577 global@vortexglobal.com www.vortexglobal.com Darlington, United Kingdom Vortex Latin America (785) 309-2138 ventas@vortexglobal.com es.vortexglobal.com Vortex Asia Pacific 86 (0) 21-5835-0100 asia.pacific@vortexglobal.com www.vortexglobal.cn For more information on how dustless loading spouts can improve safety and profitability in your facility, contact:

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